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MODEL 200A
NITROGEN OXIDES ANALYZER
TOLL-FREE: 800-324-5190
FAX: 858-657-9816
TEL: 858-657-9800
E-MAIL: api-sales@teledyne.com
WEB SITE: www.teledyne-api.com
02246
REV. F1
Copyright 2005 API Inc. 19 August 2005
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
SAFETY MESSAGES
Your safety and the safety of others is very important. We have provided many important safety
messages in this manual. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others. Each safety
message is associated with a safety alert symbol. These symbols are found in the manual and
inside the instrument. The definition of these symbols is described below:
Technician Symbol: All operations marked with this symbol are to be performed
by qualified maintenance personnel only.
Electrical Ground: This symbol inside the instrument marks the central safety
grounding point for the instrument.
CAUTION
The analyzer should only be used for the purpose
and in the manner described in this manual.
If you use the analyzer in a manner other than that for which
it was intended, unpredictable behavior could ensue with
possible hazardous consequences.
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TABLE OF CONTENTS
SAFETY MESSAGES ......................................................................................................II
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LIST OF FIGURES
FIGURE 2-1: REMOVAL OF SHIPPING SCREWS & CHECK FOR CORRECT POWER ....................................... 2-3
FIGURE 2-2: REAR PANEL ........................................................................................................................ 2-4
FIGURE 2-3: INLET AND EXHAUST VENTING ............................................................................................ 2-5
FIGURE 2-4: FRONT PANEL .................................................................................................................... 2-10
FIGURE 2-5: ASSEMBLY LAYOUT ........................................................................................................... 2-11
FIGURE 4-1: BLOCK DIAGRAM ................................................................................................................. 4-2
FIGURE 4-2: EXTERNAL PUMP PACK ........................................................................................................ 4-8
FIGURE 5-1: SAMPLE MENU TREE ............................................................................................................ 5-2
FIGURE 5-2: SETUP MENU TREE............................................................................................................... 5-3
FIGURE 6-1: IZS OPTION - PERMEATION TUBE INSTALLATION ................................................................ 6-7
FIGURE 7-1: CALIBRATION SETUP ............................................................................................................ 7-3
FIGURE 7-2: DIAGRAM OF GPT CALIBRATION SYSTEM ......................................................................... 7-21
FIGURE 8-1: REPLACING THE PARTICULATE FILTER................................................................................. 8-4
CAUTION................................................................................................................................................ 8-7
FIGURE 8-2: MOLYBDENUM CONVERTER ASSEMBLY .............................................................................. 8-8
FIGURE 8-3: REACTION CELL ASSEMBLY ............................................................................................... 8-10
FIGURE 8-4: PNEUMATIC DIAGRAM - STANDARD CONFIGURATION ....................................................... 8-12
FIGURE 8-5: PNEUMATIC DIAGRAM WITH ZERO/SPAN VALVE OPTION .................................................. 8-13
FIGURE 8-6: PNEUMATIC DIAGRAM WITH IZS OPTION .......................................................................... 8-14
FIGURE 9-1: SPAN CALIBRATION VOLTAGE ........................................................................................... 9-25
FIGURE 9-2: CPU BOARD JUMPER SETTINGS ......................................................................................... 9-36
FIGURE 9-3: RS-232 PIN ASSIGNMENTS ................................................................................................ 9-40
FIGURE 9-4: V/F BOARD SETTINGS ........................................................................................................ 9-46
FIGURE 9-5: POWER SUPPLY MODULE LAYOUT ..................................................................................... 9-51
FIGURE 9-6: ELECTRICAL BLOCK DIAGRAM .......................................................................................... 9-52
FIGURE 9-7: OZONE GENERATOR SUBSYSTEM ....................................................................................... 9-56
FIGURE 9-8: FLOW/PRESSURE SENSOR ................................................................................................... 9-59
FIGURE 9-9: NOX SENSOR MODULE ....................................................................................................... 9-60
FIGURE 9-10: NOX SENSOR MODULE ..................................................................................................... 9-61
FIGURE 9-11: PMT COOLER SUBSYSTEM ............................................................................................... 9-63
FIGURE 9-12: HIGH VOLTAGE POWER SUPPLY....................................................................................... 9-65
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LIST OF TABLES
TABLE 2-1: FINAL TEST AND CALIBRATION VALUES ............................................................................. 2-12
TABLE 2-1: FINAL TEST AND CALIBRATION VALUES (CONTINUED)....................................................... 2-13
TABLE 4-1: FRONT PANEL STATUS LED'S ............................................................................................... 4-5
TABLE 4-2: OZONE GENERATOR START-UP TIMING ................................................................................. 4-9
TABLE 5-1: M200A SAMPLE MENU STRUCTURE ..................................................................................... 5-4
TABLE 5-2: M200A SETUP MENU STRUCTURE ........................................................................................ 5-5
TABLE 5-3: M200A MENU STRUCTURE - SETUP MENU #2 ...................................................................... 5-6
TABLE 5-4: M200A MENU STRUCTURE - SETUP MENU #3 ...................................................................... 5-6
TABLE 5-5: DAS DATA CHANNEL EDITING ........................................................................................... 5-16
TABLE 5-6: CALIBRATE, SETUP PASSWORDS ......................................................................................... 5-20
TABLE 5-7: M200A OPERATING MODES................................................................................................ 5-22
TABLE 5-8: STATUS OUTPUT PIN ASSIGNMENTS .................................................................................... 5-23
TABLE 5-9: RS-232 PORT SETUP - FRONT PANEL .................................................................................. 5-25
TABLE 5-10: RS-232 SWITCHING FROM TERMINAL MODE TO COMPUTER MODE.................................. 5-26
TABLE 5-11: RS-232 TERMINAL MODE EDITING KEYS ......................................................................... 5-26
TABLE 5-12: RS-232 COMMAND SUMMARY .......................................................................................... 5-29
TABLE 5-13: RS-232 COMMAND SUMMARY .......................................................................................... 5-30
TABLE 5-14: RS-232 INTERFACE COMMAND TYPES .............................................................................. 5-31
TABLE 5-15: RS-232 TEST MESSAGES ................................................................................................... 5-32
TABLE 5-16: RS-232 WARNING MESSAGES ........................................................................................... 5-33
TABLE 5-17: RS-232 CALIBRATION COMMANDS ................................................................................... 5-34
TABLE 5-18: RS-232 CALIBRATION EXAMPLES ..................................................................................... 5-35
TABLE 5-19: RS-232 CALIBRATION MESSAGES ..................................................................................... 5-36
TABLE 5-20: RS-232 DIAGNOSTIC COMMAND SUMMARY ..................................................................... 5-37
TABLE 6-1: ZERO/SPAN VALVE OPERATION ............................................................................................ 6-2
TABLE 6-2: IZS SEQUENCE MODES.......................................................................................................... 6-3
TABLE 6-3: IZS SEQUENCE ATTRIBUTES ................................................................................................. 6-4
TABLE 6-4: IZS SEQUENCE EXAMPLE ...................................................................................................... 6-4
TABLE 6-5: EXAMPLE OF AUTOCAL SETUP .............................................................................................. 6-5
TABLE 7-1: TYPES OF ZERO/SPAN CHECK AND CALIBRATION ................................................................. 7-2
TABLE 7-2: MANUAL ZERO CALIBRATION PROCEDURE - ZERO GAS THRU SAMPLE PORT....................... 7-4
TABLE 7-3: ENTER EXPECTED SPAN GAS CONCENTRATIONS PROCEDURE ............................................... 7-5
TABLE 7-4: MANUAL SPAN CALIBRATION PROCEDURE - SPAN GAS THRU SAMPLE PORT ....................... 7-5
TABLE 7-5: MANUAL ZERO CALIBRATION PROCEDURE - Z/S VALVES .................................................... 7-6
TABLE 7-6: MANUAL SPAN CALIBRATION PROCEDURE - Z/S VALVES..................................................... 7-6
TABLE 7-7: ENABLING DYNAMIC ZERO/SPAN.......................................................................................... 7-8
TABLE 7-8: ENABLING CAL-ON-NO2 .................................................................................................. 7-10
TABLE 7-9: IZS OR Z/S VALVES MODES WITH REMOTE CONTACT CLOSURE ........................................ 7-11
TABLE 7-10: ACTIVITY MATRIX FOR CALIBRATION EQUIPMENT AND SUPPLIES .................................... 7-13
TABLE 7-11: ACTIVITY MATRIX FOR CALIBRATION PROCEDURE ........................................................... 7-14
TABLE 7-12: ZERO CALIBRATION PROCEDURE ...................................................................................... 7-22
TABLE 7-13: EXPECTED SPAN GAS CONCENTRATION PROCEDURE ........................................................ 7-23
TABLE 7-14: SPAN CALIBRATION PROCEDURE....................................................................................... 7-23
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We recognize that the need for information in this manual changes as time passes. When the
instrument first arrives, it is necessary to get it up and running quickly and verify its correct
operation. As time passes, more detailed information is often required on special configurations,
calibration alternatives and other operational details. Finally there is the need for periodic
maintenance and to quickly troubleshoot problems to assure maximum reliability and data
integrity.
To address these needs, we have created three indexes to the information inside. They are:
Table of Contents:
Outlines the contents of the manual in the order the information is presented. This is a good
overview of the topics covered in the manual. There is also a list of Tables and a list of Figures.
The Menu Index (Figure 5-1 and Figure 5-2, Table 5-1 and Table 5-2) briefly describes the front
panel menus and refers you to other sections of the manual that have a detailed explanation of
each menu selection.
Troubleshooting Section 9:
The Troubleshooting Section, outlined in the Table of Contents, allows you to diagnose and
repair the instrument based on variables in the TEST menu, the results of DIAGNOSTIC tests,
and performance faults such as excessive noise or drift. The troubleshooting section also
explains the operation, adjustment, diagnosis and testing of each instrument subsystem.
If you are unpacking the instrument for the first time, please refer to Getting Started in
Section 2.
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2 GETTING STARTED
2.1 Unpacking
1. Verify that there is no apparent shipping damage. If damage has occurred please advise
shipper first, then Teledyne API.
CAUTION
To avoid personal injury, always use two persons to
lift and carry the Model 200A.
2. Before operation, it is necessary to remove the shipping hold-down screws. Remove the
instrument cover, then refer to Figure 2-1 for screw location.
3. Also check for internal shipping damage, and generally inspect the interior of the
instrument to make sure all circuit boards and other components are in good shape and all
boards are seated properly.
4. Please check the voltage and frequency label on the rear panel of the instrument for
compatability with the local power before plugging in the M200A.
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WARNING
Analyzer Exhaust – O3 Scrubber – Pump
Pack Danger – Analyzer exhaust contains ozone.
Ozone scrubber must always be present
between analyzer exhaust and pump.
Vent pump exhaust to well ventilated area at atmosphere
pressure FIRE or EXPLOSION HAZARD.
Do not use charcoal treated with halogen compounds –
use only Teledyne API P/N 00596 charcoal.
WARNING
Lethal voltages present inside case.
Do not operate with cover off during normal operation.
Before operation check for correct input
voltage and frequency.
Do not operate without proper chassis grounding.
Do not defeat the ground wire on power plug.
Turn off analyzer power before disconnecting
electrical subassemblies.
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Figure 2-1: Removal of Shipping Screws & Check for Correct Power
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7. When the instrument is warmed up, re-check the TEST functions against Table 2-1. All
of the readings should compare closely with those in the Table. If they do not, see Section
9.1.1. The next task is to calibrate the analyzer. There are several ways to do a calibration,
they are summarized in Table 7-1. For a preliminary checkout we recommend calibration
with zero air and span gas coming in through the sample port. The procedure is:
Step 1 - Enter the expected NOx and NO span gas concentrations:
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1. As defined by USEPA.
2. Defined as twice the zero noise level.
3. At constant temperature and voltage.
4. Bi-polar.
5. Electrical rating for CE Mark compliance.
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Under the designation, the Analyzer may be operated with or without the following options:
1. Rack mount with slides.
2. Rack mount without slides, ears only.
3. Rack mount for external pump w/o tray.
4. Stainless steel zero/span valves.
5. Internal zero/span.
6. NO2 permeation tube - uncertified 0.4ppm @ 0.7 lpm.
7. NO2 permeation tube - certified 0.4ppm @ 0.7 lpm.
8. NO2 permeation tube - certified 0.8ppm @ 0.7 lpm.
9. NO2 permeation tube - uncertified 0.8ppm @ 0.7 lpm.
10. 4-20mA, isolated outputs.
11. Status outputs.
12. RS-232 output.
13. Internal pump or external pump.
14. 1 micron sample filter.
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3.3 Warranty
WARRANTY POLICY (02024c)
Prior to shipment, Teledyne API equipment is thoroughly inspected and tested. Should
equipment failure occur, Teledyne API assures its customers that prompt service and support
will be available.
COVERAGE
After the warranty period and throughout the equipment lifetime, Teledyne API stands ready to
provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in
the industry. All maintenance and the first level of field troubleshooting is to be performed by
the customer.
Equipment provided but not manufactured by Teledyne API is warranted and will be repaired to
the extent and according to the current terms and conditions of the respective equipment
manufacturers warranty.
GENERAL
Teledyne API warrants each Product manufactured by Teledyne API to be free from defects in
material and workmanship under normal use and service for a period of one year from the date of
delivery. All replacement parts and repairs are warranted for 90 days after the purchase.
If a Product fails to conform to its specifications within the warranty period, Teledyne API shall
correct such defect by, in Teledyne API's discretion, repairing or replacing such defective
Product or refunding the purchase price of such Product.
The warranties set forth in this section shall be of no force or effect with respect to any Product:
(i) that has been altered or subjected to misuse, negligence or accident, or (ii) that has been used
in any manner other than in accordance with the instruction provided by Teledyne API or (iii)
not properly maintained.
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All units or components returned to Teledyne API should be properly packed for handling and
returned freight prepaid to the nearest designated Service Center. After the repair, the equipment
will be returned, freight prepaid.
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NO + O 3 ⎯
⎯→ NO 2 * +O 2
NO 2 * ⎯
⎯→ NO 2 + hv
The reaction of NO with ozone results in electronically excited NO2 molecules as shown in the
first equation above. The excited NO2 molecules release their excess energy by emitting a
photon and dropping to a lower energy level as shown in the second equation. It has been shown
that the light intensity produced is directly proportional to the [NO] concentration present.
The Analyzer samples the gas stream and measures the [NO] concentration by digitizing the
signal from the Analyzer's photomultiplier tube (PMT). A valve then routes the sample stream
through a converter containing heated molybdenum to reduce any NO2 present to NO by the
following reaction:
315o C
3 NO 2 + Mo ⎯
⎯→ 3 NO + MoO3
The Analyzer now measures the total NOx concentration. The [NOx] and [NO] values are
subtracted from each other by the built-in computer yielding the [NO2] concentration. The three
results [NO], [NOx], and [NO2] are then further processed and stored by the computer yielding
several instantaneous and long term averages of all three components. These readings are also
stored internally in the M200A’s data acquisition system (DAS).
The software uses an adaptive filter to accomodate rapid changes in concentration. The
algorithm monitors the rate of change in concentration for both the NO and NOx channels. When
a change in concentration is detected, the software changes the sample filters to rapidly respond
to the change. The filters are adjusted to minimize the errors introduced by the time delay
between the NOx and NO channel measurements; this assures accurate NO2 measurements.
When the rate of change decreases, the filters are lengthened to provide good signal/noise ratio.
The parameters used to operate the adaptive filter have been tuned to match the electrical and
pneumatic characteristics of the M200A.
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The M200A displays all pressures in inches of mercury-absolute (in-Hg-A). Absolute pressure is
the reading referenced to a vacuum or zero absolute pressure. This method was chosen so that
ambiguities of pressure relative to ambient pressure can be avoided.
For example, if the vacuum reading is 25" Hg relative to room pressure at sea level the absolute
pressure would be 5" Hg. If the same absolute pressure was observed at 5000 ft altitude where
the atmospheric pressure was 5" lower, the relative pressure would drop to 20" Hg, however the
absolute pressure would remain the same 5" Hg-A.
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The computer memory is divided into 3 sections: ROM memory contains the multi-tasking
operating system code plus the instructions that run the instrument. The RAM memory is used to
hold temporary variables and current concentration data. The EEPROM memory contains the
instrument set-up variables such as range and instrument ID number. The EEPROM data is non-
volatile so the instrument can lose power and the current set-up information is preserved.
The display consists of 2 lines of 40 characters each. The top line is divided into 3 fields, and
displays information. The first field is the mode field. A list of operating modes is given in
Table 5-7.
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The center field displays TEST values. The TEST functions allow you to quickly access many
important internal operating parameters of the M200A. This provides a quick check on the
internal health of the instrument. The right hand field shows current concentration values of NO,
NOx, and NO2. The display scrolls between the 3 values every 4 seconds.
4.2.5.1 Keyboard
The second line of the display contains eight fields. Each field defines the key immediately
below it. By redefining the keys dynamically it is possible to simplify the instrument electronics
and user interface.
When entering data in the keyboard, if the entered value is not accepted, the M200A will "beep"
to notify the user that the value keyed in was not accepted. The original value remains
unchanged.
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A catalytic scrubber contained in the moly converter assembly removes the ozone present in the
exhaust stream.
If the external pump is selected, This option is not available with the internal pump.
The external Pump Pack includes a vacuum pump and optional charcoal NO2 scrubber. By using
this pump, it is possible to remove a significant source of acoustic noise and vibration from the
immediate area of the analyzer. The pump pack is supplied with 0.25" tube fitting to connect to
the exhaust fitting on the M200A rear panel. See Figure 2-3 for hook-up information. Plugging
the power cord into an AC outlet turns on the pump pack, see Figure 4-2.
The internal pump has slightly lower performance specifications, and shorter MTBF, however it
consumes significantly less power, and makes an instrument that has a single chassis. The NO2
scrubber option.
A pump is supplied as standard equipment, however if another pump is used, it must have the
following characteristics:
2. The ozone scrubber must remove all ozone from the analyzer exhaust.
3. Connect the exhaust (Figure 2-3) to a pump with <3 m of 1/4" PTFE tubing.
Failure to meet the performance specifications will result in poor analyzer performance, damage
to the pump, damage to the analyzer, and may jeopardize warranty repairs. Teledyne API
strongly recommends that the factory supplied pump be used with the M200A.
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NOTE
On vacuum vs absolute pressure:
Many vacuum gauges read relative to ambient pressure, therefore
a reading of 25" of mercury (Hg) at sea level (which would give an
absolute pressure of about 5" Hg in the reaction cell) would read
only 20" Hg at high altitude sites. Therefore in this manual the vacuum
specification of 5" Hg pressure is given as an absolute pressure
- 5"Hg-A - reference against zero absolute pressure (a perfect vacuum)
thus removing ambiguities for high altitude sites.
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CAUTION
Lethal voltages present inside ozone generator.
Do not defeat electrical interlock.
The dry air supply for the ozone generator uses a membrane drier to supply air with a dew point
of 0o C or less. The exhaust side of the membrane is connected to the vacuum manifold at the
rear of the instrument.
Normal room air contains enough water vapor to damage the generator and components
downstream. To prevent damage, the generator will be turned ON after 30 min following a cold
start. Otherwise, the starting of the generator will follow the table below:
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5 SOFTWARE FEATURES
The M200A control software has two major operating modes. The SAMPLE mode is the normal
mode when the instrument is taking data. The software menu that covers the SAMPLE mode is
diagrammed in Figure 5-1.
When the instrument is initially installed, or problems indicate a need for diagnostics, the
SETUP menu is used. The SETUP menu is diagrammed in Figure 5-2.
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Setup Menu #3
Reference
Level 1 Level 2 Level 3 Level 4 Description
Section
VARS Internal variables 5.3.9, 9.2
PREV, PREV, NEXT scroll up and 5.3.9, 9.2
NEXT, down through the VARS menu.
JUMP, JUMP will go to variable
EDIT number selected, EDIT will
allow editing of the selected
variable
DIAG Diagnostic menu 5.3.7, 9
PREV, PREV, NEXT scroll up and 5.3.7, 9
NEXT down through the DIAG menu
SIG I/O Examines, changes analog and 9.1.3.1
digital internal signals
ANALOG Writes test voltages to analog 9.1.3.5
OUT outputs
D/A CAL Calibrates analog outputs 9.1.3.6
OPTIC Activates Optic Test feature 9.1.3.3
TEST
ELEC Activates Electric Test feature 9.1.3.2
TEST
O3 GEN Turns OFF/ON ozone generator 9.1.3.4
RS-232 Writes test data to RS-232 port 9.1.3.7
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One of the features of the SAMPLE mode is TEST functions. The TEST functions can be
examined while the instrument is taking data, and can be used to determine if the instrument is
set up and functioning properly.
Section 5.2.1 defines each TEST function and explains its use.
NOTE
In any of the following TEST functions, if a value of
XXXX is displayed, that indicates an off scale and
therefore meaningless reading.
To use the TEST functions to diagnose instrument faults, refer to Troubleshooting Section 9.1.
Range
1. In single range mode there is one range for all 3 outputs. This is the default range mode.
2. Independent range mode allows different ranges for each output. When enabled, there are
three range values displayed, NO, NOx and NO2.
3. Auto range mode allows a low range and high range. The M200A will automatically
switch to the other range dynamically as concentration values require. The TEST values will
show the range the instrument is currently operating in, and will dynamically display the
alternate range as the range changes occur.
NOTE
Each of the range modes Single range, Autorange, and
Independent ranges are mutually exclusive.
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Stability
The instrument noise is computed using the standard deviation of the last 10 minutes of data,
with the value being computed at the end of each NO/ NOx cycle. It is computed for the NOx
channel only. The value only becomes meaningful if sampling a constant concentration for more
than 20 minutes, so the various software filters can stabilize. The value shown should be
compared to the value observed in Table 2-1.
Sample Flow
The SAMPLE FLOW test function is computed from the pressure measured up-stream of the
sample flow orifice. The pressure down-stream of the orifice is also checked to assure the
assumptions of the equation are valid. SAMPLE FLOW will indicate variations in flow caused
by changes in atmospheric pressure, but will not detect a plugged sample flow orifice. The
nominal value is 500 ± 50 cc/min.
Ozone Flow
The OZONE FLOW test function is directly measured by a solid state flow meter. Variations in
this value indicate variations in ozone flow. The nominal value for ozone flow is 60 - 90 cc/min.
PMT Voltage
The PMT VOLTAGE shows the PMT signal at the output of the preamp board. The waveform
of the PMT voltage can be complex, and vary from near 0 mV when zero gas is in the reaction
cell to 5000 mV when a high concentration of NOx is being measured. If the PMT reading is
consistently 5000 mV, that indicates an off-scale reading. Typical readings bounce around,
which is normal.
Like the PMT Voltage TEST function above, the NORMALIZED PMT VOLTAGE measures
the PMT signal at the output of the preamp board. The difference here is that several
normalization functions are applied to this signal before it is displayed. The most important is the
temperature and pressure compensation factors. If NORM PMT is used as suggested in the
Factory Calibration Procedure (Section 9.1.6) the M200A will be correctly calibrated.
AZERO Voltage
This test measurement is the AUTOZERO voltage. It indicates the most recent reading from the
AutoZero circuit. The units are mV and from – 20 to 150 are acceptable.
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The HVPS reading is a measure of the scaled-up HVPS programming voltage. The voltage used
to set the HVPS output is generated on the Preamp board. Its value is between 0 and 1 volt,
corresponding to a voltage of 0 to 1000 volts out of the HVPS. The HVPS front panel TEST
measurement should be greater than 450 volts and will typically be around 600-800V.
The DCPS voltage is a composite of the 5 and ± 15 VDC voltages in the Power Supply Module.
This is meant to be a quick indicator to show if the PSM is working correctly. The nominal value
is 2500 mV ± 200 mV.
This is a measurement of the temperature of the reaction cell. It is controlled by the computer to
50 ± 1° C. Temperatures outside this range will cause the M200A output to drift.
Box Temperature
This TEST function shows the temperature inside the chassis of the M200A. The temperature
sensor is located on the Status/Temp Board. Typically it runs 2 to 10° C higher than the ambient
temperature. The M200A has been engineered to maintain stable output over 5 to 40° C ambient
temperature range.
PMT Temperature
IZS Temperature
The IZS option has an oven for NO2 permeation tubes. The oven temperature is nominally 50° C.
The permeation tube temperature is stable to ± 0.1° C, although it is normal to see the
temperature on the front panel move ± 0.4° C due to the proximity of the temp sensor to the
heater. It can be adjusted from the front panel by pressing SETUP-MORE-VARS and selecting
the IZS_SET item and entering the desired temperature. Using this adjustment, the permeation
rate of the NO2 permeation tube can be adjusted to a desired value. See Section 6.3 for
information on adjusting the IZS temperature.
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Moly Temperature
The moly temperature is controlled by the computer. The nominal set-point is 315 ± 5° C. The
temperature sensor inside the moly is a type-J thermocouple. The thermocouple amplifier is
located on the STATUS/TEMP board. If the thermocouple breaks, the reading will go to 500° C
and turn off power to the heater.
The pressure in the reaction cell is measured by a solid state pressure sensor which measures
absolute pressure. Absolute pressure was chosen because it is an unambiguous measure of cell
pressure. This pressure will vary depending on several things.
Nominal values are 3 to 10 in-Hg-A. Typical readings are about 5 in-Hg-A for the external
pump, and about 8 in-Hg-A or better for the internal pump.
Sample Pressure
The pressure in the sample inlet line is measured by a solid state pressure sensor which measures
absolute pressure. Absolute pressure was chosen because it is an unambiguous measure of
sample pressure. This pressure typically runs 0.5" or so below atmospheric pressure due to the
pressure drop in the sample inlet lines.
The coefficients of two (NOx and NO) straight line equations determine the calibration of the
M200A. The values of these parameters can be used to determine the quality of the calibration.
These 4 parameters contain valuable information about the quality and validity of the calibration.
Refer to Section 5.2.2.5 for more information on the formulas. Refer to Section 7.10 Calibration
Quality for details on how to use these values.
Time
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5.2.2.3 Span
Pressing the SPAN key along with ENTR will cause the instrument to adjust the SLOPE value of
the internal formula so the instrument displays the span value. The expected NOx and NO span
concentrations must be entered before doing a SPAN calibration. See Table 7-3.
Like the Zero calibration, the Span cal cannot be done with any concentration of span gas. If the
signal level is outside certain limits the, SPAN key will not be illuminated. If you encounter this
condition see Section 9.2.9. It is also possible at low levels of span concentration that BOTH the
ZERO and SPAN keys might be on, thus allowing you to either zero or span the instrument. In
this case, care must be taken to perform the correct operation or the analyzer can become mis-
calibrated.
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To compute the NOx and NO concentrations, the formula for a straight line is used.
Where:
In comparison with analog analyzers the slope term is equivalent to the "span pot" and the b term
is equivalent to the "zero pot". Again, like an analog analyzer there is only a limited range of
adjustment allowed for either term, and there are consequences of having the values near the
high or low limits of their respective ranges.
The x term is the conditioned PMT signal. PMT signal is adjusted for the AutoZero background,
range, temperature, and pressure.
The offset (b) term is the total background light with the AutoZero term subtracted out.
The AutoZero term measures detector dark current, amplifier noise, and ozone generator
background. Therefore, in the case of the NO channel the b term should be very close to zero. In
the NOx channel the b term is composed mostly of the molybdenum converter background.
After every zero or span calibration, it is very important to check the QUALITY of the
calibration. The calibration of the M200A involves balancing several sections of electronics and
software to achieve an optimum balance of accuracy, noise, linearity and dynamic range.
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To disable the compensation, press CAL-CONC-MOLY-SET and enter 1.0000 as the efficiency.
Factory default is 1.0000.
The logged parameters are stored in what are called “Data Channels.” Each Data Channel can
store multiple data parameters. The Data Channels can be programmed and customized from the
front panel. A set of default Data Channels has been included in the M200A software. For more
information on programming custom Data Channels, a supplementary document containing this
information can be requested from Teledyne API.
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The M200A comes pre-programmed with a set of useful Data Channels for logging
concentration and predictive diagnostic data. The default Data Channels can be used as they are,
or they can be changed by the user to fit a specific application. They can also be deleted to make
room for custom user-programmed Data Channels.
The data in the default Data Channels can be viewed through the SETUP-DAS-VIEW menu.
Use the PREV and NEXT buttons to scroll through the Data Channels and press VIEW to view
the data. The last record in the Data Channel is shown. Pressing PREV and NEXT will scroll
through the records one at a time. Pressing NX10 and PV10 will move forward or backward 10
records. For Data Channels that log more than one parameter, such as PNUMTC, buttons labeled
<PRM and PRM> will appear. These buttons are used to scroll through the parameters located
in each record.
CONC: Samples NOx, NO and NO2 concentration data at one minute intervals and
stores an average every hour with a time and date stamp. Readings during
calibration and calibration hold off are not included in the data. The last 800
hourly averages are stored.
PNUMTC: Collects sample flow and sample pressure data at five minute intervals and
stores an average once a day with a time and date stamp. This data is useful for
monitoring the condition of the pump and critical flow orifice (sample flow)
and the sample filter (clogging indicated by a drop in sample pressure) over
time to predict when maintenance will be required. The last 360 daily averages
(about 1 year) are stored.
CALDAT: Logs new slope and offset every time a zero or span calibration is performed,
also records the sample concentration reading just prior to performing a
calibration.
NOTE:
This Data Channel collects data based on an event (a calibration) rather than a
timer. This Data Channel will store data from the last 200 calibrations. This
does not represent any specific length of time since it is dependent on how often
calibrations are performed. As with all Data Channels, a time and date stamp is
recorded for every data point logged.
The attributes of the data collecting channels can be changed, and new data collectors can be
defined. A comprehensive guide to programming the DAS interface is available separately from
Teledyne API, order “DAS Manual” p/n 02837. Table 5-5 is an example of changing a DAS
channel attribute.
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If the range you select is between 50 and 2000 ppb the front panel will read the concentration
anywhere from 0 to 2000 ppb regardless of the range selected. If the range selected is from 2001
to 20,000 ppb the front panel will read from 0 to 20,000 ppb. The apparently wider range of front
panel readouts is because the M200A has 2 internal hardware ranges, namely 0-2000 ppb and 0-
20,000 ppb. The analog output is scaled for the range selected, however the front panel reading
can display correct concentrations over the entire physical range.
NOTE
Only one of the following range choices can be active at any one time.
If the range is changed such that the physical range switches, the
instrument should be recalibrated. Since the gain is 10x lower on the
0-20,000 ppb range, the offsets may be a factor of 10 less also.
1. Single Range
2. Auto Range
3. Independent Ranges
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To set up Auto Range press SETUP-RNGE-MODE-AUTO, then press ENTR. To set the values
press SETUP-RNGE-SET. The M200A will prompt you for LO, then HI which is the lower and
upper ranges of Auto Range. Key in the values desired, then press ENTR.
To set up Independent Ranges press SETUP-RNGE-MODE-IND, then press ENTR. To set the
values press SETUP-RNGE-SET. The M200A will prompt you for the range of NO, NOx and
NO2 channels. Key in the desired range for each channel, press ENTR after each value.
The software scales the diluted sample gas concentration readings so that the outputs show the
actual stack concentrations. Also, when calibrating the instrument or setting the ranges, the
values selected are scaled to reflect the actual stack concentrations. The scaled readings are sent
to the display, analog outputs, and RS-232 port.
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1. SELECT UNITS
For stack measurement, select PPM units. To set units, press SETUP-RANGE-UNIT-PPM.
Press ENTR after the unit selection is made, then EXIT to return to upper level menus.
The dilution ratio of the probe is entered by SETUP-RANGE-DIL. Accepted values are 1 to
1000. Press ENTR, and EXIT to return to upper level menus. A value of 1 disables the
dilution feature.
3. SELECT RANGE
The range selection is the same with dilution as with normal monitoring. See Section 5.3.4
for information on range selection. You should note however, the value entered should be the
actual concentration of the calibration gas entering the dilution probe. The units of this
number is ppm.
4. CALIBRATION
When the above selections have been made, the instrument now must be calibrated through
the dilution probe.
NOTE
Units are now in PPM. See Section 7 for calibration methods.
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NH3 ppb x 0.76 = NH3 ug/m3 - for use with the M201A NH3 analyzer
To change the current units press SETUP-RNGE-UNIT from the SAMPLE mode and select the
desired units.
NOTE
The expected span concentration values in the new units must be
re-entered into the analyzer and the unit re-calibrated using one
of the methods in Section 7.
Changing units affects all of the RS-232 values, all of the
display values, and all of the calibration values.
Example:
If the current units are in ppb and the NO span value is
400 ppb, and the units are changed to ug/m3. A new value
must be entered for the expected span concentration.
The offset is set in the V/F calibration menu. Press SETUP-MORE-DIAG, scroll to A/D
CALIBRATION, then press ENTR. Select CFG-SET-OFFSET, then enter the desired offset and
press ENTR. Press EXIT to return to the SAMPLE mode.
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If you are having trouble with the clock running slow or fast, the speed of the clock can be
adjusted by selecting the CLOCK_ADJ variable in the SETUP-MORE-VARS menu. The units
of CLOCK_ADJ are seconds per day.
The M200A software and hardware has been designed and tested to operate properly during the
year 2000 calendar rollover.
The instrument ID number can also be set. This ID number is attached to every RS-232 message
sent by the M200A. To set the ID press SETUP-MORE-COMM-ID and enter a 4 digit number
from 0000-9999, then press ENTR.
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1. First is a comprehensive command interface for operating and diagnosing the analyzer in
interactive fashion. This mode is for use by a human operator issuing commands to the
instrument.
2. Second is the equivalent command interface described above, but with the interface set
up to be operated by a computer program rather than interactive commands.
3. The interface can also provide an audit trail of analyzer events. In this function the port
sends out messages about instrument events like calibration or warning messages. If these
messages are captured on a printer or remote computer, they provide a continuous audit trail
of the analyzers operation and status.
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Second is physical wiring of the analyzer to the other unit. We have incorporated into the
Analyzer LED's that signal the presence of data on the communications lines, and also switches
to easily re-configure the analyzer from DCE to DTE if necessary. In addition the front panel
diagnostics allow test data streams to be sent out of the port on command. This flexibility and
diagnostic capability should simplify attaching our equipment to other computers or printers. If
problems occur, see the Troubleshooting Section 9.3.2.
There are 2 additional RS-232 setups that can be done via the front panel.
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NOTE
To enter the correct value, ADD the decimal values of the features you
want to enable. For example if LOGON and front panel RS-232
menus are desired, the value entered would be 4 + 8 = 12.
Port Communication
The RS-232 can be set up in interactive or computer mode of communication. If the port is
attached to a computer running an instrument interface program, it needs to have different
characteristics than if used interactively by a human operator.
When an operator is communicating with the analyzer via a terminal, the analyzer should be
placed into TERMINAL MODE, which echoes keystrokes, allows editing of the command line
using the backspace and escape keys, and allows recall of the previous command. When a host
computer or data logger is connected to the analyzer, it should be placed into COMPUTER
MODE, which does not echo characters received or allow the special editing keys. See Table 6-5
for relevant commands.
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If the command line doesn't seem to respond to keystrokes or commands, one of the first things
you should do is send a Control-T to switch the command line interface into terminal mode.
Also, some communication programs remove CTRL-T and CTRL-C characters from the byte
stream, therefore these characters will not be sent to the analyzer. Check your communications
program owners manual.
In terminal mode, all commands must be terminated by a carriage return; commands are not
processed until a carriage return is entered. While entering a command you may use the
following editing keys:
Words such as T, SET, LIST, etc. are called keywords and are shown on the help screen in
uppercase, but they are not case-sensitive. You must type the entire keyword(s), separated by
spaces; abbreviations are not accepted.
NOTE
To open the help screen, Type "?" and press the Enter key.
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Security Feature
The RS-232 port is often connected to a public telephone line which could compromise
instrument security. If the LOGON feature is implemented the port has the following attributes:
The RS-232 LOGON feature must be enabled from the front panel by setting bit 4. See
Table 6-4. Once the feature is enabled, to logon type:
LOGON 940331
940331 is the default password. The password can be changed to any number from 0 to 999999
by the variable RS232_PASS. To change the password enter the command:
V RS232_PASS=NNNNNN
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Communication Protocols
1. Teledyne API protocol – some of the features of this protocol are covered in Section 5.5.2. A
comprehensive manual is available separately as p/n 01350 RS-232 Programming Notes.
2. Alternate protocol – this protocol is used for communicating on proprietary networks.
3. Multidrop protocol – used for communication with multiple Teledyne API instruments on a
single RS-232 line. A manual is available separately as Teledyne API p/n 01842 Multidrop
Programming Manual.
If this bit is set, the instrument will send a setup string out the RS-232 port at power-up. The
string correctly sets up a US Robotics Sportster Modem. No other brands of modem are
supported at this time.
Allows the software to ignore certain errors involving the computation of parity.
Setting this bit causes instrument to issue a command prompt after each command output. Useful
when operating in Terminal Mode.
The Teledyne API RS-232 interface includes multidrop capability, to permit the connection of
more than one analyzer to a single RS-232 line. To identify each Analyzer, an optional ID
number is permitted for all commands. If you don’t include the ID number in the command, all
of the instruments connected to the RS-232 interface will respond. If you include the ID number
in the command, only the instrument whose ID number matches will execute the command.
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Reporting of status messages for use as an audit trail is one of the two principal uses for the RS-
232 interface. You can effectively disable the asynchronous reporting feature by setting the
interface to quiet mode. All messages output from the analyzer (including those output in
response to a command line request) have the format:
DDD:HH:MM is a time-stamp indicating the day-of-year (DDD) as a number from 1 to 366, the
hour of the day (HH) as a number from 00 to 23, and the minute (MM) as a number from 00 to
59.
MESSAGE contains warning messages, test measurements, DAS reports, variable values, etc.
The uniform nature of the output messages makes it easy for a host computer to parse them.
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There are 5 different types of messages output by the M200A. The meanings of the various
messages are discussed elsewhere in the manual. The TEST, DIAGNOSTIC and WARNING
messages are discussed in Section 9.1, 9.2, 9.3. DAS and VARIABLES are discussed in Section
5.3.3 and 5.3.9. CALIBRATE is discussed in Section 7.
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1
Displayed when independent range is enabled.
2
Displayed when single or auto range is enabled.
3
Depends on which units are currently selected.
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Whenever a warning message is reported on the analyzer display, if the RS-232 interface is in
the normal mode(i.e. not in quiet mode) the warning message is also sent to the RS-232
interface. These messages are helpful when trying to track down a problem with the analyzer and
for determining whether or not the DAS reports are actually valid. The warning message format
is for example:
Individual warnings may be cleared via the front panel or the command line interface. To clear
the sample flow warning shown above the command would be:
W WSAMPFLOW
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Whenever the analyzer starts or finishes an IZS calibration, it issues a status report to the RS-232
interface. If the RS-232 interface is in the normal mode, these reports will be sent. Otherwise,
they will be discarded. Table 5-19 shows the format of the text of the calibration messages. An
example of an actual sequence of calibration status messages is:
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D ENTER SIG
D OZONE_GEN=ON
D EXIT
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D PRINT
D PRINT "name”
For example to print the properties of the CONC data channel enter:
D PRINT “CONC”
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Automatic RS-232 reporting can be independently enabled and disabled for each Data Channel.
For all default data channels, automatic reporting is initially set to “OFF.” If this property is
turned on, the Data Channel will issue a report with a time and date stamp to the RS-232 port
every time a data point is logged. The report format is shown below:
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All of the default Data Channels sample more than one parameter, for these channels, each
parameter is printed on a separate line.
There is also a compact format. If this attribute is enabled, all 3 concentration parameters are
printed on one line as shown below:
To change any of the attributes of a particular data channel, the channel attributes are edited
from the front panel. The following table uses the example of Automatic Reporting. Other
attributes can be edited in a similar fashion.
A list of variables and their settings can be requested over the RS-232 port by:
The output from this command is long and will not be shown here. The general format of the
output is:
Where:
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Variables can be changed. Before changing the settings on any variables, please make sure you
understand the consequences of the change. We recommend you call the factory before changing
the settings on any variables. The general format for changing the settings on a variable is:
For example to change the warning limits on the box temperature type:
V BOX_SET 30 10 50
The CONFIG command lists the software configuration. To show the software configuration,
type:
V CONFIG
In addition to SAMPLE and SETUP modes the M200A has a number of additional operational
modes. They are listed in Table 5-5. To list the analyzer's current mode type:
V MODE
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1. Sample mode. Here both valves are de-energized and sample gas passes through the
sample/cal valve and into the analyzer.
2. Zero mode. The sample/cal valve is energized to the cal mode. The zero/span valve is de-
energized in the zero mode, thus allowing zero gas to be admitted through the rear panel
bulkhead fitting into the analyzer.
3. Span mode. The sample/cal valve is energized and in the cal mode. The zero/span valve
is energized in the span mode. With both valves on, span gas is admitted through a rear panel
bulkhead fitting into the analyzer.
Zero air and span gas inlets should supply their respective gases in excess of the 500 cc/min
demand of the Analyzer. Supply and vent lines should be of sufficient length and diameter to
prevent back diffusion and pressure effects. See Figure 2-3 for fitting location and tubing
recommendations.
Adequate zero air can be supplied by connecting a Purafil/charcoal scrubber and 5 micron
particulate filter (Teledyne API P/N 000369) to the zero air inlet tubing. The zero air scrubber
used in conjunction with the Zero/Span Valve option provides an inexpensive source of zero air.
Another source of zero air is the Model 701 zero air generator.
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The IZS system operation is similar to the zero/span valve operation, except that the source of
the zero air and span gas are supplied at the analyzer via a scrubber and permeation tube
respectively. See Section 7.1 - calibration for operational details. A continuous purge flow of
approximately 60 cc/min is drawn across the permeation tube to prevent span gas accumulation
when the permeation tube is not in use.
If the instrument is going to be turned off for more than 8 hours, the permeation tube must be
removed from the oven. The perm tube continues to release gas even while at room temp thus
causing high concentrations of NO2 gas to accumulate. The high NO2 levels cause high
background readings when operation is resumed.
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For each mode there are seven attributes that the MODE can have that control operational details
of the SEQUENCE. They are:
Do a span check ½ hour later every other day, lasting 15 minutes, without calibration.
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The NO2 concentration is determined by the permeation tube specific output (ng/min @ 1 slpm
@ 50o C), the permeation tube temperature (o C) and the air flow across it (slpm). The specific
output in ng/min is a fixed function of the permeation tube and is noted on shipping container.
The ng/min units can be converted to ppb units by the following equation:
Where:
perm tube output (ng/min) = The perm tube output in nanograms/minute
46 gr/mole NO2 = The molecular weight of nitrogen dioxide (NO2)
560 cc/min = The flow rate of zero air over the permeation tube
24,500cc/mole = The volume of air (at 25 C and 1 atm pressure) that contains 1 mole of air
molecules
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
If an ammonia permeation tube is being used, substitute the molecular weight of NH3 (17
g/mole) for that of NO2.
The temperature is set at 50.0o C. Check SETUP-MORE-VARS and scroll to the IZS-SET
variable to verify that the temperature is properly set. It should be set to 50o C with over-and-
under temperature warnings set at 49o C and 51o C. There is a 60 cc/min flow across the
permeation tube at all times to prevent build-up of NO2 gas in the tubing.
If desired, the output of the permeation tube can be adjusted by adjusting the oven temperature
up or down slightly. The adjust increment is 0.1o C to facilitate small adjustments of the setpoint
temperature.
WARNING
Do not leave instrument turned off for more than 8 hours
without removing the permeation tube. Do not ship the
instrument without removing the permeation tube. The
tube continues to emit NO2, even at room temperature
and will contaminate the entire instrument.
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TELEDYNE API recommends that you purchase replacement permeation tubes from:
VICI METRONICS
2991 Corvin Drive
Santa Clara, CA 95051 USA
Phone 408-737-0550 Fax 408-737-0346
The M200A uses 560 cc/min of zero air over the perm tube. Therefore you should order a
permeation tube with a SPECIFIC OUTPUT of 400 to 450 ppb at .560 liter/minute. This will
give you a IZS Span response of 80 to 90% of full scale in the 500 ppb range. Refer to the above
equation for calculating other concentrations and instrument flow rates.
Once the Analyzer and permeation tube have stabilized, the response to the permeation tube is
not expected to change more than ± 5%. If, during a periodic span check, the response varies by
more than 5%, or more importantly, shows drift, then there may be a problem with the Analyzer
or permeation tube, see Section 9.3.9.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
We strongly recommend that SPAN CALIBRATION be done with NO span gas, although it is
possible with NO2 (see Section 7.6), or with gas from a GPT system. SPAN CHECKS can be
done with either NO only, NO2 only or a mixture of NO and NO2 (GPT).
Zero air used for all calibration procedures, including GPT, should have < .1 ppb NO or NO2,
less than 1 ppb of major interferents such as SO2 and NH3, and a dew point of -5o C or less. The
calibration gasses should be from a reliable supplier, since the quality of the tank concentration
values ultimately determines the accuracy of the analyzer. EPA protocol calibration gasses
should be used for EPA monitoring, see Section 7.8.
NOTE
If you are using the M200A for EPA monitoring, only the
calibration method described in Section 7.8 should be used.
NOTE
If there are any problems completing any of the following procedures,
refer to Section 9.2.8 and 9.2.9 - Unable to Span or Zero.
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Since the zero gas concentration is defined as 0 ppb, it is not necessary to enter the expected zero
value. Table 7-2 details the zero calibrate procedure with zero gas coming in through the sample
port.
Table 7-2: Manual Zero Calibration Procedure - Zero Gas Thru Sample Port
Step Number Action Comment
1. Press CAL The M200A enters the calibrate mode from sample mode. The
zero gas must come in through the sample port.
2. Wait 10 min Wait for reading to stabilize at zero value.
3. Press ZERO If you change your mind after pressing ZERO, you can still
press EXIT here without zeroing the instrument.
4. Press ENTR Pressing ENTR actually changes the calculation equations.
5. Press EXIT M200A returns to sampling. Immediately after calibration,
data is not added to the DAS averages.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
If desired, compensation for moly converter efficiency (CE) can be included in the NOx
concentration calculation. The CE must be entered prior to calibration. Refer to Section 7.8.6 for
the CE procedure.
Table 7-4: Manual Span Calibration Procedure - Span Gas thru Sample Port
Step Number Action Comment
1. Press CAL The M200A enters the calibrate mode. NO span gas should be
fed to the sample port.
2. Wait 10 min Wait for reading to stabilize at span value.
3. Press SPAN If you change your mind after pressing SPAN, you can still
press EXIT here without spanning the instrument.
4. Press ENTR Pressing ENTR actually changes the calculation equations and
causes the instrument to read the NO and NOx span
concentrations.
5. Press EXIT M200A returns to sampling. Immediately after calibration,
data is not added to the DAS averages.
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It is not possible to calibrate the M200A on a NO2 permeation tube unless the CAL-ON-NO2
option is enabled. This is because the NO2 permeation tube contains no NO gas. We recommend
a NO tank with calibration certificate for complete calibration or see CAL-ON-NO2 Section 7.6.
To do a manual zero check with the IZS Option, press CALZ, then wait about 10 minutes for the
zero reading to stabilize. The zero value in the display, and analog output is the zero value. Press
EXIT to return to SAMPLE mode. This procedure does not change the zero calibration of the
instrument.
To do a manual NO2 check, press CALS, then wait about 10 minutes for the NO2 reading to
stabilize. The concentration value in the display, and analog output is the span value. Press EXIT
to return to SAMPLE mode. This procedure does not change the span calibration of the
instrument.
Before proceeding with enabling DYNAMIC Z/S you must setup the AUTOCAL feature.
Enabling AUTOCAL is described in Table 6-2. To enable DYNAMIC Zero/Span Calibration:
7-7
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
NOTE
If you try a Dynamic span calibration using the NO2 permeation tube
as a calibration gas source, the NO channel concentration will be zero
due to the lack of NO in the NO2 permeation tube. An error message
will be displayed, CANNOT CALIBRATE. We recommend a calibrated
NO tank for complete calibration. Also see the CAL-ON-NO2 option.
With dynamic calibration turned on, the instrument will re-set the slope and offset values for the
NO and NOx channel each day. This continual re-adjustment of calibration parameters can often
mask subtle fault conditions in the analyzer. It is recommended that if Dynamic Cal is enabled,
the TEST functions, and SLOPE and OFFSET values in the M200A are checked frequently to
assure high quality and accurate data from the instrument.
7-8
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
CAUTION
This feature has some unexpected side effects.
If CAL-ON-NO2 is enabled and you do a SPAN CHECK or SPAN CAL, the NO2 concentration
will be reported as ZERO! This is because all of the NO2 gas is being routed through the
molybdenum converter during both the NO and NOx portions of the measurement cycle. Thus
the instrument sees the SAME concentration of NO gas in the NO and NOx channels, and
reports a NO2 concentration of zero.
As long as CAL-ON-NO2 is enabled the instrument will never report any NO2 during span
calibration. This feature should be enabled only when a calibration is desired, otherwise leave it
disabled so that NO2 concentrations are reported correctly. See Table 7-8 to enable this feature.
NOTE
Note that this method of calibration is NOT approved by the USEPA.
Permeation tubes are known to change as temperatures are cycled,
and as they age. Also, this calibration relies on the moly converter
to be working properly. (Converter efficiency can be compensated
by enabling the Converter Efficiency option.) It is recommended that
if CAL-ON-NO2 is used, the instrument calibration be checked
frequently by independent means to assure accurate data.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Once CAL-ON-NO2 is enabled the procedure for zeroing and spanning the instrument is
identical to that given in Section 7.2 for Zero/Span Valves.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
In order to do another remote check, both contact closures should be held open for at least 1
second, then may be set again. Table 7-9 shows what type of check is performed based on the
settings of the two contact closures.
Table 7-9: IZS or Z/S Valves Modes with Remote Contact Closure
Ext Zero CC Ext Span CC Operation
Contact Open Contact Open State when in SAMPLE mode, normal monitoring
Contact Open Contact Closed Span check or calibrate*
Contact Closed Contact Open Zero check or calibrate*
7-11
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
In order to insure that high quality, accurate measurements are obtained at all times, the M200A
must be calibrated prior to use. A quality assurance program centered on this aspect and
including attention to the built-in warning features of the M200A, periodic inspection, regular
zero/span checks and routine maintenance is paramount to achieving this.
In order to have a better understanding of the factors involved in assuring continuous and
reliable information from the M200A, it is strongly recommended that Publication No. PB 273-
518 Quality Assurance Handbook for Air Pollution Measurement Systems (abbreviated, Q.A.
Handbook) be purchased from the NTIS (phone 703-487-4650). Special attention should be paid
to Section 2.3 which deals with chemiluminescent-based NO2 analyzers and upon which most of
this section is based. Specific regulations regarding the use and operation of ambient oxides of
nitrogen analyzers can be found in 40 CFR 50 and 40 CFR 58. Both publications are available
from the U.S. Government Printing Office (phone 202-783-3238).
All monitoring instrument systems are subject to some drift and variation in internal parameters
and cannot be expected to maintain accurate calibration over long periods of time. Therefore, it
is necessary to dynamically check the calibration relationship on a predetermined schedule. Zero
and span checks must be used to document that the data remains within control limits. These
checks are also used in data reduction and validation. Table 7-10 summarizes the initial quality
assurance activities for calibrating equipment. Table 7-11 is a matrix for the actual dynamic
calibration procedure.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Calibrations should be carried out at the field monitoring site. The Analyzer should be in
operation for at least several hours (preferably overnight) before calibration so that it is fully
warmed up and its operation has stabilized. During the calibration, the M200A should be in the
CAL mode, and therefore sample the test atmosphere through all components used during
normal ambient sampling and through as much of the ambient air inlet system as is practicable.
If the instrument will be used on more than one range, it should be calibrated separately on each
applicable range, see Section 7.9. Calibration documentation should be maintained with each
analyzer and also in a central backup file.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Care must be taken to assure that no oxygen is allowed in the NO tank, regulator, or sample
lines. If oxygen is present, it reacts with NO to produce NO2 which can lead to significant errors
in NO concentration measurement.
It is good practice to request a NOx analysis from the supplier of the NO calibration gas.
Generally the maximum NO2 impurity that should be allowed is 1% of the NO concentration.
The NO2 impurity in the NO standard can be measured by the M200A. A procedure is given in
the TAD for NO2 measurement.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
The principle of GPT is based on the rapid gas phase reaction between NO and O3 which
produces stoichiometric quantities of NO2 as shown by the following equation:
NO + O 3 ⎯
⎯→ NO 2 + O 2
Given that the NO concentration is known for this reaction, the resultant concentration of NO2
can be determined. Ozone is added to excess NO in a dynamic calibration system as shown in
Figure 7-2, and the NO channel of the chemiluminescent analyzer detects the changes in NO
concentration. After the addition of O3, the observed decrease in NO concentration on the
calibrated NO channel is equivalent to the concentration of NO2 produced. The amount of NO2
generated may be varied by adding varying amounts of O3 from a stable O3 generator. All zero
air used in this procedure should conform to the requirements stated in Section 7.
Dynamic calibration systems based on this principle are commercially available, or may be
assembled by the user. A recommended calibration system is described in the Federal Register1
and detailed in TAD.2
The following procedures and equations should be used to determine whether an existing GPT
calibration system will meet required conditions for a specific calibration.
For calibrators that have known pre-set flow rates, use equations 7-5 and 7-6 of steps 7 and 8
(below) to verify the required conditions. If the calibrator does not meet specifications, follow
the complete procedure to determine what flow modifications must be made.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
1. Select an NO standard gas that has a nominal concentration in the range of 50 to 100
ppm. Determine the exact concentration [NO]STD by referencing against an NIST-SRM, as
discussed in Section 2.0.7 (Q.A. Handbook).
2. Determine the volume (cm3) of the calibrator reaction chamber (VRC). If the actual
volume is not known, estimate the volume by measuring the approximate dimensions of the
chamber and using an appropriate formula.
3. Determine the required minimum total flow output (FT) using Equation 7-1:
If more than one analyzer is to be calibrated at the same time, multiply FT by the number of
analyzers.
4. Calculate the NO concentration [NO]OUT needed to approximate 90% of the URL of the
NO2 analyzer to be calibrated, using Equation 7-2:
5. Calculate the NO flow (FNO) required to generate the NO concentration [NO]OUT, using
Equation 7-3:
[NO ] OUT x F T
F NO = Equation 7-3
[NO ] STD
6. Calculate the required flow through the ozone generator (FO), using Equation 7-4:
[NO ] STD X F NO X V RC
Fo = - F NO Equation 7-4
2.75 ppm - min
7. Verify that the residence time (tR) in the reaction chamber is <2 min, using Equation 7-5:
VRC
tR = ≤ 2 min Equation 7-5
FO + FNO
8. Verify that the dynamic parameter specification (PR) of the calibrator's reaction chamber
is >2.75 ppm-min using Equation 7-6:
PR = [NO ]STD ×
FNO VRC
× ≥ 2.75 Equation 7-6
FO + FNO FO + FNO
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
NOTE
If tr is >2 minutes or if PR is <2.75 ppm-min, changes in flow conditions
(FT, FO, FNO) or in the reaction chamber volume (VRC), or both will
have to be made, and tr and PR will have to be re-calculated.
9. After equations 7-5 and 7-6 are satisfied, calculate the diluent air flow (FD) using
Equation
7-7:
1. Determine the minimum total flow (FT) required at the output manifold using Equation 7-
1:
7-18
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Because low flows are difficult to control and measure, it is often advantageous to set a higher
total flow than needed. In this example, we will let FT = 2750 cm3/min
2. Determine the highest NO concentration, [NO]OUT, required at the output manifold, using
Equation 7-2:
3. Calculate the NO flow (FNO) required to generate the NO concentration [NO]OUT, using
Equation 7-3:
4. Calculate the required flow rate through ozone generator (FO) using Equation 7-4:
5. Verify that the residence time (tR) in the reaction chamber is <2 min using Equation 7-5:
180 cm3
tR = = 0.63 min
260 cm3 / min+ 24.5 cm3 / min
6. Verify the dynamic parameter specification (PR) of the calibrator reaction chamber using
Equation 7-6:
7. Calculate the diluent air flow (FD) required at the mixing chamber, using Equation 7-7:
7-19
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Calibration must be performed with a calibrator that meets all conditions specified in Subsection
2.3.2 (Q.A. Handbook). Flow settings used in the GPT calibration for NO2 must be determined
as illustrated in Section 7.8.4, this manual.
The user should be sure that all flow meters are calibrated under the conditions of use against a
reliable standard. All volumetric flow rates should be corrected to 25o C (78oF) and 760 mm
(29.92 in.) Hg. Calibrations of flow meters are discussed in TAD.2
Gas Phase Titration (GPT) requires the use of the NO channel of the analyzer to determine the
amount of NO2 generated by titration. Therefore it is necessary to calibrate and determine the
linearity of the NO channel before proceeding with the NO2 calibration. It is also necessary to
calibrate the NOx channel. This can be done simultaneously with the NO calibration. During the
calibration the M200A should be operating in its normal sampling mode, and the test atmosphere
should pass through all filters, scrubbers, conditioners, and other components used during
normal ambient sampling and as much of the ambient air inlet system as is practicable. All
operational adjustments to the M200A should be completed prior to the calibration. The
following software features must be set into the desired state before calibration.
1. Automatic Converter Efficiency compensation. See Sections 7.8.6 and 7.9, this manual.
2. Independent range selection. See Sections 5.3.4 and 7.9, this manual.
3. Automatic temperature/pressure compensation. See Table 9-5.
4. Alternate units, make sure ppb units are selected for EPA monitoring. See Section
5.3.4.5.
5. Autoranging option. See Section 5.3.4.2.
Converter efficiency should be set prior to calibration since its value is used in the computation
of the NOx and NO2 concentration outputs.
The analyzer should be calibrated on the same range used for monitoring.
If AutoRanging or Independent range options are selected the highest of the ranges will result in
the most accurate calibration, and should be used.
Make sure the GPT calibration system can supply the range of concentrations at a sufficient flow
over the whole range of concentrations that will be encountered during calibration.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
NOTE:
The analyzer does not operate the zero/span valves in this mode,
the zero gas enters through the sample port.
2. Wait 10 min Wait for reading to stabilize at the zero value.
3. Press ZERO If you change your mind after pressing ZERO, you can still
press EXIT here without zeroing the instrument.
4. Press ENTR Pressing ENTR actually changes the calculation equations.
5. Press EXIT M200A returns to the SAMPLE mode.
F NO x [NO ] STD
[NO ] OUT = Equation 7-8Enter the respective concentrations using the
FT
procedure in Table 7-13. The expected span concentrations need not be re-entered each time a
calibration is performed unless they are changed.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Sample the generated concentration until the NO and the NOx responses have stabilized.
The analog voltage output should measure 80% of the voltage range selected. (e.g. 4.00 VDC if
0-5V output is selected.) The readings on the front panel display should be equal to the expected
NO and NOx concentrations entered in the procedure given in Table 7-13 above. See the
Troubleshooting Section 9.2.8 if there are problems. Also see the Calibration Quality Check
procedure Section 7.10.
After the zero and the 80% URL points have been set, generate five approximately evenly
spaced calibration points between zero and 80% URL without further adjustment to the
instrument. Allow the instrument to sample these intermediate concentrations for about 10
minutes each and record the instrument NO and NOx responses.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Plot the analyzer NO and NOx responses versus the corresponding calculated concentrations to
obtain the calibration relationships. Determine the straight line of best fit (y = mx + b)
determined by the method of least squares.
After the best-fit line has been drawn for the NO and the NOx calibrations, determine whether
the analyzer response is linear. To be considered linear, no calibration point should differ from
the best-fit line by more than 2% of full scale.
NOTE
During this procedure do not make any adjustments to the instrument.
1. Generate an NO concentration near 90% of the URL. Dilution air and O3 generator air
flows should be the same as used in the calculation of specified conditions of the dynamic
parameter according to Section 7.8.4. Sample this NO concentration until the NO and NOx
responses stabilize. Record the NO and NOx concentrations.
2. Turn on and adjust the O3 generator in the calibrator to produce sufficient O3 to decrease
the NO concentration to about 10% of full scale. This will be equivalent to 80% of the URL
of the NO2 channel. After the analyzer responses stabilize, record the resultant NO, NOx, and
NO2 concentrations.
IF THE NOx READING SHOULD DROP TO LESS THAN 96% OF ITS STARTING
VALUE DURING THIS STEP, IT INDICATES THE MOLY CONVERTER IS IN NEED
OF TROUBLESHOOTING OR REPLACEMENT. SEE SECTION 7.8.6 FOR FURTHER
DETAILS.
3. While maintaining all other conditions, adjust the ozone generator to obtain several other
concentrations of NO2 evenly spaced between the 80% URL point and the zero point. Record
the NO, NOx, and NO2 concentrations for each additional point.
7-24
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
F NO * [ NO 2 ] IMP
[ NO 2 ] OUT = [NO ] ORIG - [NO ] REM + Equation 7-10
FT
Where:
[NO]ORIG is the NO concentration before the GPT ozone is turned on, and [NO]REM is the NO
remaining after GPT.
5. Plot the NO2 concentration output by the instrument on the y-axis against the generated
NO2 [NO2]OUT on the x-axis. The plot should be a straight line within the ± 2% linearity
criteria given for the NOx and NO channels. If the plot is not linear the most likely cause is
that the converter needs replacing. See Section 7.8.6 on Moly converter efficiency.
Where:
[NOx]ORIG is the NOx concentration before the GPT ozone is turned on, and [NOx]REM is the
NOx remaining after GPT.
2. Plot the [NO2]CONV concentration output by the instrument on the y-axis against the
concentration generated [NO2]OUT on the x-axis. The plot should be a straight line within the
± 2% linearity criteria given for the NOx and NO channels.
3. Determine the best straight line fit of the plot either by inspection or least squares. The
slope of the resulting straight line is the moly efficiency. The value should be between .96
and 1.02. If not, the moly needs to be replaced.
4. If you want the M200A to automatically compensate (Section 7.8.6.1) for converter
efficiency, enter the efficiency value in the front panel by CAL-CONC-MOLY-SET, then
key in the slope from step 3 followed by ENTR. Press EXIT to return to the SAMPLE menu.
7-25
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
7-26
Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
1. No later than three months after the most recent calibration or performance audit which
indicated analyzer calibration to be acceptable.
2. An interruption of more than a few days in analyzer operation.
3. Any repairs which might affect its calibration.
4. Physical relocation of the analyzer.
5. Any other indication (including excessive zero or span drift) of possible significant
inaccuracy of the analyzer.
Following any of the activities listed above, the zero and span should be checked to determine if
a calibration is necessary. If the analyzer zero and span drifts exceed the calibration limits in
Table 9-1 of Section 2.0.9, Subsection 9.1.3 (Q.A. Handbook), a calibration should be
performed.
Essential to quality assurance are scheduled checks for verifying the operational status of the
monitoring system. The operator should visit the site at least once each week. Every two weeks a
Level 1 zero and span check must be made on the analyzer. Level 2 zero and span checks should
be conducted at a frequency desired by the user. Definitions of these terms are given in Table 7-
16.
In addition, an independent precision check between 0.08 and 0.10 ppm must be carried out at
least once every two weeks. Table 7-17 summarizes the quality assurance activities for routine
operations. A discussion of each activity appears in the following sections.
For information on shelter and sample inlet system, an in-depth study is in Field Operations
Guide for Automatic Air Monitoring Equipment, Publication No. APTD-0736, PB 202-249 and
PB 204-650, U.S. Environmental Protection Agency, Office of Air Programs, October 1972.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Table 7-16: Definition of Level 1 and Level 2 Zero and Span Checks
(from Section 2.0.9 of Q.A. Handbook for Air Pollution Measurment Systems)
LEVEL 1 ZERO AND SPAN CALIBRATION LEVEL 2 ZERO AND SPAN CHECK
A Level 1 zero and span calibration is a A Level 2 zero and span check is an "unofficial"
simplified, two-point analyzer calibration used check of an analyzer's response. It may include
when analyzer linearity does not need to be dynamic checks made with uncertified test
checked or verified. (Sometimes when no concentrations, artificial stimulation of the
adjustments are made to the analyzer, the Level 1 analyzer's detector, electronic or other types of
calibration may be called a zero/span check, in checks of a portion of the analyzer, etc.
which case it must not be confused with a Level
Level 2 zero and span checks are not to be used
2 zero/span check.) Since most analyzers have a
as a basis for analyzer zero or span adjustments,
reliably linear or near-linear output response with
calibration updates, or adjustment of ambient
concentration, they can be adequately calibrated
data. They are intended as quick, convenient
with only two concentration standards (two-point
checks to be used between zero and span
concentration). Furthermore, one of the standards
calibrations to check for possible analyzer
may be zero concentration, which is relatively
malfunction or calibration drift. Whenever a
easily obtained and need not be certified. Hence,
Level 2 zero or span check indicates a possible
only one certified concentration standard is
calibration problem, a Level 1 zero and span (or
needed for the two-point (Level 1) zero and span
multipoint) calibration should be carried out
calibration. Although lacking the advantages of
before any corrective action is taken.
the multipoint calibration, the two-point zero and
span calibration--because of its simplicity--can If a Level 2 zero and span check is to be used in
be (and should be) carried out much more the quality control program, a "reference
frequently. Also, two-point calibrations are easily response" for the check should be obtained
automated. Frequency checks or updating of the immediately following a zero and span (or
calibration relationship with a two-point zero and multipoint) calibration while the analyzer's
span calibration improves the quality of the calibration is accurately known. Subsequent
monitoring data by helping to keep the Level 2 check responses should then be
calibration relationship more closely matched to compared to the most recent reference response
any changes (drifts) in the analyzer response. to determine if a change in response has
occurred. For automatic Level 2 zero and span
checks, the first scheduled check following the
calibration should be used for the reference
response. It should be kept in mind that any
Level 2 check that involves only part of the
analyzer's system cannot provide information
about the portions of the system not checked and
therefore cannot be used as a verification of the
overall analyzer calibration.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Sample introduction No moisture, foreign Weekly visual inspection Clean, repair, or replace
system material, leaks, as needed
obstructions; sample
line connected to
manifold
Recorder 1. Adequate ink & Weekly visual inspection 1. Replenish ink and
paper paper supply
2. Legible ink traces 2. Adjust time to agree
3. Correct chart with clock; note on
speed and range chart
4. Correct time
Analyzer operational 1. TEST Weekly visual inspection Adjust or repair as
settings measurements at needed
nominal values
2. M200A in
SAMPLE mode
Analyzer operational Zero and span within Level 1 zero/span every 2 1. Find source of error
check tolerance limits as weeks; Level 2 between and repair
described in Subsec. Level 1 checks at
2. After corrective
9.1.3 of Sec. 2.0.9 frequency desired by user
action, re-calibrate
(Q.A. Handbook)
analyzer
Precision check Assess precision as Every 2 weeks, Subsec. Calc, report precision,
described in Sec. 2.0.8 3.4.3 (Ibid.) Sec. 2.0.8 (Ibid.)
and Subsec. 3.4.3
(Ibid.)
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
1. Provide data to allow analyzer adjustment for zero and span drift;
2. Provide a decision point on when to calibrate the analyzer;
3. Provide a decision point on invalidation of monitoring data.
Items 1 and 2 are described in detail in Subsection 9.1.3 of Section 2.0.9 (Q.A. Handbook). Item 3 is
described in Subsection 9.1.4 of the same section.
Refer to the Troubleshooting Section 9 of this manual if the instrument is not within the allowed
variations.
Zero and Span can be checked from the front panel keyboard. The procedure is in Section 7.1
of this manual.
2. Automatic Zero/Span Checks
After the appropriate setup, Z/S checks can be performed automatically every night. See
Table 6-2 and Section 7.4 of this manual for setup and operation procedures.
3. Zero/Span checks via remote contact closure
Zero/Span checks can be initiated via remote contact closures on the rear panel. See Section
7.7 of this manual.
4. Zero/Span via RS-232 port
Z/S checks can be controlled via the RS-232 port. See Section 5.5 of this manual for more
details.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Evidence of good quality data includes documentation of the quality control checks and the
independent audits of the measurement process by recording data on specific forms or on a quality
control chart and by using materials, instruments, and measurement procedures that can be traced to
appropriate standards of reference. To establish traceability, data must be obtained routinely by
repeated measurements of standard reference samples (primary, secondary, and/or working
standards). More specifically, working calibration standards must be traceable to standards of higher
accuracy, such as those listed below in Table 7-18.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Table 7-18: NIST-SRM's Available for Traceability of Calibration and Audit Gas
Standards
Nominal
NIST-SRM4 Type Size, at STP
Concentration
1683a Nitric oxide in N2 870 50 ppm
1684a Nitric oxide in N2 870 100 ppm
1685a Nitric oxide in N2 870 250 ppm
Permeation Tubes
Concentration, ppm
4 Permeation rate,
NIST-SRM Type at flow rates of:
ug/min
1 L/min/5 L/min
1629 Nitrogen dioxide 1.0 0.5/0.1
Cylinders of working gas traceable to NIST-SRM's (called EPA Protocol Calibration Gas) are also
commercially available (from sources such as Scott Specialty Gases, etc.).
NOTE
If the assayed concentration of NO2 impurity in the NO cylinder,
[NO2]imp, is greater than the 1 ppm value allowed in the calibration
procedure, make certain that the NO delivery system is not the
source of contamination before discarding the NO standard.
The NO content of the NO working standard must be periodically assayed against NIST-traceable
NO or NO2 standards. Any NO2 impurity in the cylinder must also be assayed. Certification of the
NO working standard should be made on a quarterly basis or more frequently, as required.
Procedures are outlined below for certification against NO traceable standard. The simplest and most
straightforward procedure is to certify against an NO standard.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
Then, generate several NO concentrations by diluting the NO working standard. Use the nominal
NO cylinder concentration, [NO]NOM, to calculate the diluted concentrations. Plot the analyzer
NO response (in ppm) versus the nominal diluted NO concentration and determine the slope,
SNOM. Calculate the NO concentration of the working standard [NO]STD from:
NOTE
For further information on calibration by GPT and NO2 permeation
devices, refer to part 50 of Chapter 1, Title 40 CFR, Appendix F
(revised December 1, 1976) and Reference 13 of that Appendix.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
1. When doing a span calibration of the M200A use 80% of the highest of the ranges. This
will result in the most accurate calibration.
2. When selecting concentrations for the NO/NOx or NO2 (GPT) dynamic calibrations use
80% of the highest AutoRange or the highest Independent Range. This will produce the most
accurate calibration.
3. If the calibration data is obtained from the RS-232 port or from the front panel display,
no special changes are necessary if the instrument is in AutoRange or Indep. Range. This is
because the internal hardware and software has sufficient dynamic range to cover the entire
EPA equivalent range, also those features only affect the analog outputs.
4. If using the analog outputs and a chart recorder or datalogger, be sure to note when
AutoRange occurs so that the correct range is used. With Independent Ranges, change the
ranges so that all ranges are equal to the highest range so that all calibration data is on scale.
5. Calibration curves or relationships should be obtained for each range used.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
The following procedure checks the Slope and Offset parameters in the equations used to
compute the NO, and NOx concentrations. It is important that they fall within certain limits with
respect to themselves and to each other. For an explanation of the use of these terms in the
concentration calculation see Section 5.2.2.5.
The slope and offset parameters are similar to the span and zero pots on an analog instrument.
Just as in the analog instrument, if the slope or offset get outside of a certain range, the
instrument will not perform as well.
The slope value will be slightly different on the NO and NOx channels. This is due to slight
differences in pneumatic resistance in each pathway. If the slopes are significantly different,
there is a calibration error or a cross port leak in the switching valve. If there is a sudden change
in slopes after a calibration, that usually indicates a change in reaction cell pressure. This
generally requires a Factory Calibration covered in Section 9.1.6.
The offset value gives information about the background signal level. Check the observed offset
value against the factory value in Table 2-1. If significantly higher, check Section 9.1.6. Also,
after calibration check the AutoZero reading and compare it against the factory checkout value.
Increasing readings are a predictor of problems.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
After the above procedure is complete, the M200A is ready to measure sample gas.
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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. F1
7.11 References
1. Environmental Protection Agency, Title 40, Code of Federal Regulations, Part 50,
Appendix F, Measurement Principle and Calibration Procedure for the Measurement of
Nitrogen Dioxide in the Atmosphere (Gas Phase Chemiluminescence), Federal Register, 41
(232): pp 52688-52692, December 1976.
2. Ellis, Elizabeth C. Technical Assistance Document for the Chemiluminescence
Measurement of Nitrogen Dioxide, U.S. Environmental Protection Agency, Research
Triangle Park, NC. October 1976. 91 p.
3. Quality Assurance Requirements for State and Local Air Monitoring Stations (SLAMS),
Appendix A, Federal Register, Vol. 44, No. 92, pp 27574-27582, May 1979.
4. Catalog of NBS Standard Reference Materials. NBS Special Publication 260, 1975-76
Edition. U.S. Department of Commerce, NBS. Washington, D.C. June 1975.
5. Quality Assurance Handbook for Air Pollution Measurement Systems - Volume I,
Principles. EPAN-600/9-76-005. December 1984.
6. Quality Assurance Handbook for Air Pollution Measurement Systems - Volume II,
Ambient Air Specific Methods. EPA-600/4-77/027a, December 1986.
7. Quality Assurance Requirements for Prevention of Significant Deterioration (PSD) Air
Monitoring, Appendix B, Federal Register, Vol. 44, No. 92, pp 27582-27584, May 1979.
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8 MAINTENANCE
8.1 Maintenance Schedule
NOTE
The operations outlined in this chapter are to be
performed by qualified maintenance personnel only.
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CAUTION
The charcoal used for the ozone scrubber should NOT be
treated with halogen compounds (chlorine, iodine, etc), since
explosive compounds may be formed on contact with ozone.
4. Remove the old permeation tube. Install the new permeation tube in the same chamber
with the membrane facing UP.
5. Re-assemble the oven and turn on instrument power.
Permeation tubes require 48 hours at 50° C to reach a stable output. We recommend waiting this
long before any calibration checks, adjustments, or conclusions are reached about the permeation
tube.
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NOTE
If the instrument is to be turned off for more than 8 hours, the
perm tube must be removed from the IZS oven. Even at room
temperature the perm tube continues to release NO2. Concentrations
can build up to very high levels inside the instrument causing
contamination and high background readings.
1. Disconnect the scrubber from the rear panel pneumatic fitting and remove from the hold
down clip. While removing the cartridge, check the DFU filter for contamination and dirt,
replace if necessary.
2. Unscrew the top, remove the felt pad and empty the contents.
3. Inspect the upper and lower felt pads for signs of plugging, replace if necessary.
4. Replace with 50% Purafil(upstream) and 50% charcoal (downstream).
5. Re-install felt pad, screen and re-tighten cap. Make sure the o-ring in the cap is in good
shape and squarely seated.
6. Leak check the assembly, then re-attach scrubber to fitting and clip on rear panel.
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1. Turn off the power to the M200A and allow the converter to cool.
2. Remove the entire assembly from the chassis.
A. Remove the pneumatic fittings from the valves.
B. Remove the power to the valves, thermocouple wire and cartridge heater.
C. Remove the converter assembly from the chassis by loosening the 4 captive screws that
secure the assembly to the chassis.
CAUTION
The converter operates at 315º C. Severe burns can result
if not enough time is allowed for the assembly to cool. Do
not handle assembly until it is at room temperature.
3. Disconnect the gas fittings and power cable grounding from the can.
4. Remove the valve assembly and bottom bracket and re-attach those two parts to the
replacement moly assembly.
5. Re-attach the pneumatic fittings and valve assembly to the can.
6. Install the assembly back into the analyzer. Re-attach the electrical and pneumatic
fittings. Leak check the assembly when completed.
7. Turn the power back on. The insulation can emit a burnt odor for the first 24 hours, this is
normal. Allow the converter to burn-in for 24 hours, then re-calibrate the instrument.
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To clean the reaction cell it is necessary to remove the reaction cell from the sensor housing. Use
the following guide:
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O-RING
(P/N OR0034)
SPRING
(P/N HW0002)
FILTER
(P/N FL0001)
ORING
(P/N OR0001)
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Also inspect all pneumatic lines for cracks and abrasion on a regular basis. Replace as necessary.
Refer to the pneumatic diagram in Figure 8-4, Figure 8-5, Figure 8-6.
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CAUTION
Pressure must be less than 15 psi.
3. Pressurize system and check for leaks by watching overall pressure. The pressure should
not drop more than 2"Hg(1 psi) in 5 minutes.
If the instrument fails the pressure test, each fitting needs to be leak checked to find the location.
Be careful that the system is always pressurized so as not to draw soap solution into the
plumbing system. Make sure you dry off any accumulated bubble solution. Refer to Figure 8-4,
Figure 8-5, Figure 8-6 for pneumatic diagrams.
The Sensor module can be leak checked as a unit using a 1/8" tubing fitting on top of the
assembly. The same rules as above apply.
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If there is a response, tighten the joints or replace the tubing with new black PTFE tubing. We
often find light leaks are caused by o-rings being left out of the assembly.
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9 TROUBLESHOOTING, ADJUSTMENTS
NOTE
The operations outlined in this chapter are to be
performed by qualified maintenance personnel only.
This section of the manual contains information on diagnosing and repairing instrument
performance problems. It contains information on how to use and interpret TEST and
DIAGNOSTIC data as well as WARNING messages the instrument generates. There is
information on how to troubleshoot the instrument subsystems. Finally there is information to
perform adjustments such as DAC calibration procedures.
This manual provides troubleshooting procedures that address problems to the board level. For
component level troubleshooting, consult the schematics for the appropriate board in Appendix
A.1.
NOTE
The values of the readings shown on the front panel of the
instrument may at times read XXXXXX. This means that the
reading is off scale and therefore meaningless.
General Troubleshooting
1. If the fault is light on and it stays on after you clear the warning messages, see Section
9.1.2.
2. Think of the analyzer as three sections:
Section 1: Pneumatics - Over 50% of all analyzer problems are traced to leaks in the pump
assembly, sample filter, instrument internal pneumatics, calibrator or external sample
handling equipment. Suspect a leak first, and check Section 9.2.
Section 2: Electronics - data processing section. This can be readily checked out using
Electric Test in Section 9.1.3.2.
Section 3: Optics - Optical section consisting of PMT, HVPS, Preamp, and signal
processing. Refer to Section 9.1.3.3 on use of Optical Test.
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The above should get you started in diagnosing and repairing the most common faults. If these
reasons have been eliminated, the next thing to do is a Factory Calibration covered in Section
9.1.6 or check Section 9.2 for other fault diagnosis. If difficulties persist, contact our service
department. The 800 telephone number is on the cover page of this manual.
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Auto range option allows 2 different ranges for all outputs, and
will automatically switch to the other range dynamically as
concentration values require. The TEST values will show the
range the instrument is currently operating in, and will
dynamically display the alternate range as the range changes
occur.
STABIL Check value in The instrument stability is the Std. Deviation of the last 10 min of
Final Test Values NOx conc data. It is computed for the NOx channel only. The noise
Table 2-1 value only becomes meaningful if sampling a constant
concentration for more than 20 minutes. The noise value should be
compared to the value observed in the factory check-out.
Faults that cause high noise values are:
1. Gas leaks
2. Light leak
3. Faulty HVPS
4. Defective Preamp board
5. Outgassing Moly converter
6. PMT recently exposed to room light
7. Dirty/contaminated reaction cell
8. Mis-calibrated (slope - offset outside of limits)
SAMPLE FLW 500 cc/min ± 50 This is the instrument flow. It is computed using the up stream and
down stream pressures across the sample flow orifice. This
method can give a false flow indication if the orifice is plugged
and the sample pump is creating a pressure drop. It should be
taken into account when diagnosing instrument faults.
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When sampling zero gas the PMT reading should be less than
150 mV and relatively constant.
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Table 9-2 shows the warning messages and gives some possible causes.
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The diagnostic modes are summarized in Table 9-3. To access these functions, press SETUP-
MORE-DIAG, then press NEXT, PREV to select the desired mode, then press ENTR to select
that mode.
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NOTE:
Some signals can be toggled into states that indicate warnings
or other faults. These settings will remain in effect until DIAG
mode is exited, then the M200A will resume control over the
signals.
ANALOG OUTPUT Causes a test signal to be written to the analog output DAC's.
The signal consists of a scrolling 0%, 20%, 40%, 60%, 80%,
100% of the analog output value. The scrolling may be
stopped by pressing the key underneath the % display to hold
that value. The exact voltage values depend on the jumper
settings on the analog output buffer amplifiers.
D/A CALIBRATION The analog output is created by 4 digital-to-analog converters.
This selection starts a procedure to calibrate these outputs.
Refer to Section 9.3.3.1 for a detailed procedure.
TEST CHANNEL Allows several different internal voltages to be routed to an
analog output port. Useful for diagnosing intermittent
instrument faults.
OPTICAL TEST Sets the M200A into a known state and turns on an LED near
the PMT to test the instrument signal path. See Section 9.1.3.3
for details on using this test.
ELECTRICAL TEST Tests just the electronic portion of the PMT signal path. Used
in conjunction with optic test, see Section 9.1.3.2.
O3 GEN OVERRIDE This function controls the power to the ozone generator. It
does not indicate status of the generator.
RS-232 Causes a 1 second burst of data to be transmitted from the RS-
232 port. Used to diagnose RS-232 port problems. See Section
9.1.3.7, 9.3.2 for RS-232 port diagnostic techniques.
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Procedure:
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3. The value in PMT should come up to 2000 mV ± 500 mV in less than 15 sec.
If the HVPS or the span gain adjust on the preamp card has been changed without doing a
FACTORY CALIBRATE the reading in step 3 may be different than 2000 mV, since the
overall calibration affects ELECTRIC TEST. See Section 9.1.6 for factory calibration
procedure.
If ET is a steady 2000 ± 500 mV, that means the Power Supply Module, Preamp buffer
amplifier, V/F, CPU, and display are all working properly.
The implementation of OT involves several changes to the instrument operating conditions. The
M200A does the following when switching to optic test:
1. Saves the current instrument setup as to autorange, indep range, current range and places
the instrument into the 2000 ppb range.
2. Turns off power to the ozone generator to assure there is no interfering light from the
reaction cell.
3. Disables the AUTOZERO circuit.
4. Turns on the OT LED, the PMT reading in TEST functions should be 2000 ± 1000 mV.
To turn on OT, press SETUP-MORE-DIAG, then scroll to OPTIC TEST, then press ENTR.
If the HVPS or the span gain adjust on the preamp card has been changed without doing a
FACTORY CALIBRATE the reading in step 4 may be different than 2000 mV, since the overall
calibration affects OPTIC TEST. See Section 9.1.6 for factory calibration procedure.
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To access the VARS menu press SETUP-MORE-VARS-ENTR. Use the PREV-NEXT buttons
to select the variable of interest, then press EDIT to examine/change the value, then press ENTR
to save the new value and return to the next higher menu. If no change is required, press EXIT.
TPC_ENABLE
The M200A has temperature and pressure compensation. T/P comp adjusts the output of the
instrument for changes in sample temperature, reaction cell pressure, and atmospheric pressure.
The sample temperature is controlled by the temperature of the reaction cell. The setpoint is 50°
C, and the value of the adjustment parameter is equal to 1.0000 when the reaction cell
temperature is 50° C. The temperature compensation increases sample concentration with
increasing temperature to compensate for the drop in density of gas in the reaction cell.
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The reaction cell pressure compensation factor is equal to 1.0000 when the cell pressure is 5"-
Hg-A. The compensation factor increases sample concentration with increasing cell pressure to
compensate for increased quenching of the chemiluminescent reaction at higher pressures. The
pressure compensation correction has been found to work adequately up to about 8000 ft
(2400m) altitude.
The sample pressure compensation factor is equal to 1.0000 at 29.92"-Hg-A. This factor
increases sample concentration with decreasing sample pressure to compensate for a lower head
pressure on the sample flow orifice.
Taken together, the three factors change the output of the instrument very little. The sample
temperature is essentially invariant, and the cell pressure and sample pressure factors tend to
cancel each other. The resultant coefficient has no practical variation with pressure changes due
to weather fronts. Changes in altitude of 1000 feet usually change the output of the instrument by
about 0.5% if compensation is turned off, much less if it is operating.
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* Minimum and Maximum readings depend on the DAC 3 switch settings of the V/F board. For
the standard ±5 VDC range, minimum corresponds to 0 VDC and maximum corresponds to
5 VDC.
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NOTE
In this procedure a range of 500 ppb and a span gas concentration
of 400 ppb is used as an example. Other values can be used.
1. On the Preamp board (see Appendix for schematics), set S1 and S2 to 8. Turn R19 20
turns clockwise, then 3 turns counter-clockwise (see figure 2-5).
2. Set RANGE MODE to SNGL by SETUP-RNGE-MODE-SNGL to select single range
operation.
3. Set the RANGE to 500 ppb by SETUP-RNGE-SET and key in 500, then press ENTR.
4. Input Zero gas into the sample port, and Scroll to the TEST function labeled PMT.
Typical reading should be less than 50 mV. Readings above 150 mV indicate a pneumatic
leak, light leak, contaminated reaction cell, bad zero gas, or wet air coming into the ozone
generator. If readings are greater than ±150 mV, the instrument will not zero or span
properly, see Sections 9.2.8, 9.2.9.
5. Allow the instrument to sample zero gas for at least 20 minutes to re-fill the internal data
filters and autozero filter with zero readings. Then zero the instrument by CAL-ZERO-
ENTR.
6. Set the expected span concentration to 400ppb. Enter the expected NOx concentration of
400 ppb by pressing CAL-CONC-NOX. Then press CAL-CONC-NO, to enter the expected
NO concentration of 400 ppb. Then press EXIT to return to the CAL menu.
7. Input 400 ppb of NO span gas in the sample inlet port.
8. Scroll to the NORM_PMT - TEST function.
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For ranges up to 2000 ppb, multiply the expected span value by 2 to get the mV reading.
For ranges 2001 to 20000 ppb, multiply the expected span value by .2 to get the mV reading.
In this example the expected span gas concentration is 400 ppb and therefore the expected
voltage is 800 mV. As an alternate method, the voltage can be determined from the graph in
Figure 9-1. On the Y-axis find the calibration concentration in ppb, then determine the
expected voltage from the X-axis.
10. Adjust S2, the HVPS coarse adjustment, on the preamp board to the setting that produces
a signal that is closest to 800 mV. Adjust S1, the HVPS fine adjustment, to the setting that
produces a signal that is closest to 800 mV. Use R19 to trim the reading to 800 ± 50 mV. The
readings will periodically go to zero as the AutoZero circuit operates, ignore the zero
readings.
11. Allow the instrument to sample span gas for 30 minutes. Then do a span calibration by
CAL-SPAN-ENTR. After the span is completed, do the span quality check procedure in
Table 7-19. This procedure is extremely important to assure that the instrument will operate
with optimum noise, linearity, and dynamic range.
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1. To adjust ET press SETUP-MORE-DIAG, then scroll to ELEC TEST and press ENTR.
2. Scroll the TEST functions until PMT is displayed.
3. Adjust R27 until 2000 mV ± 100 is displayed.
4. Press EXIT to return to SAMPLE mode.
1. To adjust OT press SETUP-MORE-DIAG, then scroll to OPTIC TEST and press ENTR.
2. Scroll the TEST functions until PMT is displayed.
3. Adjust R25 until 2000 mV ± 100 is displayed.
4. Press EXIT to return to SAMPLE mode.
If this procedure does not produce an instrument that will properly span, please contact your
local distributor or the Teledyne API factory. Teledyne API's phone number is on the front page
of this manual.
NOTE
It has been our experience that about 50% of all analyzer performance
problems are sooner or later traced to leaks in some part of the system.
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If the M200A passes ET and OT, that means the instrument is capable of detecting light
and processing the signal to produce a reading. Therefore, the problem is in the
pneumatics or ozone generator.
4. Check ozone generator subsystem. Do diagnostic test of ozone generator subsystem, see
Section 9.3.6.
5. Check for disconnected electrical cables to sensor module.
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After fixing the cause of the high AutoZero filter readings, the M200A will take 15
minutes for the filter to clear itself.
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Select the PMT - TEST function. With zero gas going into the instrument, the value should be
less than 150 mV, typically less than 50 mV. If you are getting a high reading, the probable
reasons are:
1. The reading may be temporarily high if the PMT has been recently exposed to room
light. If so, let the instrument run for several hours with zero gas to get the PMT accustomed
to low light levels.
2. Leak that admits gas containing NO.
3. Contaminated reaction cell. Remove and clean cell.
4. Wet (i.e., undried ambient air) air into the ozone generator. Check the PermaPure drier
and associated plumbing for leaks and correct operation.
5. Zero gas that isn't really zero. Make sure you're not trying to zero the machine with
ambient air or span gas.
6. AutoZero filter is corrupted with high readings. To clear the AutoZero filter, input zero
gas and wait for 15 minutes for the filter to clear.
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1. V/F board DAC's out of calibration. Do DAC calibration and Factory Calibration.
2. Analog outputs electrically loaded down causing voltage to sag. Could be due to imput
impedance to chart recorder or data logger being too low or improper grounding. The
Recorder and DAS outputs do not have separate output drivers, the problem could be the
combined load of both could be too high.
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Like the display, the overall functioning of the CPU can be confirmed by a simple test.
1. Locate the CPU board on the mother board by referring to Figure 2-5.
2. Power the instrument on.
3. Locate the red LED at the top left edge of the board.
4. It should be flashing at a frequency of about once per second.
5. This flashing indicates the board is powered up and is executing instructions.
Testing and operation of the CPU RS-232 port is described in Section 9.3.2. It is possible for the
UART driver chip to malfunction in either or both of the input or output ports.
To check the operation of the keyboard, each key should perform an operation indicated by its
current definition shown on the second line of the display.
At the top level menu key #1 is defined as the TEST function. Pressing this key should cause the
middle field of the top line of the display to show the various test functions.
Example #2 - testing key #8 (right most key). At the top level menu key #8 is defined as the
SETUP key. pressing key #8 should cause the SETUP menu to be displayed.
Example #3 - If the 5 character field above any key is blank, the key is not defined, pressing the
key has no effect.
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Physical Wiring
First is to get the physical wiring hooked up correctly. Refer to Figure 9-3 for the wiring diagram
of the DB-9 plug on the M200A rear panel. There are 2 features that make connecting the wiring
easier. First is the red/green LED’s on the rear panel. The M200A provides the power to run the
red LED, the external equipment will provide the power for the green LED. If the wiring is
hooked up correctly both LED’s will be illuminated. Secondly, there is a DTE-DCE switch, this
switch interchanges pin 2 & 3 on the DB-9 connector. Set the DTE-DCE switch so that both
LED’s are illuminated.
Second is to get the communication protocol for each instrument to match. In Figure 9-3 the
default RS-232 parameters are listed. The BAUD rate can be changed in the software menus
under SETUP-MORE-COMM-BAUD.
You will need to purchase a software package so your computer can transmit and receive on its
serial port. There are many such programs, we use PROCOMM at Teledyne API. Once you set
up the variables in PROCOMM and your wiring connections are correct, you will be able to
communicate with the analyzer.
Modems are especially difficult because they may have pins that need to be at certain levels
before the modem will transmit data. The most common requirement is the Ready to Send (RTS)
signal must be at logic high (+5V to +15V) before the modem will transmit. The Teledyne API
analyzer sets pin 8 (RTS) to 10 volts to enable modem transmission. Once the physical
connection has been correctly established, it is necessary to establish the correct software
settings in the modem. If the RS-232 bit field #64 in the VARS menu has been set, the M200A
will transmit a modem setup string when the instrument is powered up. The contents of the string
are set for a US Robotics Sportster modem. We strongly recommend using this model of modem
to avoid modem connection problems.
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To troubleshoot a modem connection first disconnect the RS-232 cable from the Analyzer and
verify (use a DVM) that you are getting a signal on Pin 2 of the RS232 port on the Analyzer. The
signal will be between -5V and -15V with respect to signal ground (pin 5). If not, there is a
problem with the CPU board or the cable. This is the transmit (TD) signal out of the Analyzer.
This should then be connected to TD input on the modem, normally Pin 2. You may need to
switch the DTE/DCE switch.
Second: Go to the cable connected to the modem/terminal and verify (use a DVM) that you are
getting a –5 V to –15 V signal on Pin 3 of the cable. This pin should be connected to Pin 3 of the
Teledyne API Analyzer.
Third: (for modems) heck that the voltage level on Pin 8 of the Analyzer is between +5V and
+15V. This pin should be connected (through the cable) to Pin 4 of the modem.
Now set the baud rate of the Analyzer to the speed required by the modem and it should work. If
you are still experiencing problems, a cable adapter may be needed. Please contact the factory
for assistance.
There are two LED's on the rear panel Connector Board (01114) which are connected to pin 2
and 3 of the DB-9 connector on the board. If the switch is in the DCE position (default) the red
LED is connected to pin 3 of the DB-9 connector. When data is transmitted by the M200A the
red LED will flicker, indicating data present on this line. When the M200A is running, the LED
will normally be ON, indicating logic low. A one second burst of data can be transmitted over
the port by a command in the DIAGNOSTIC menu. Press SETUP-MORE-DIAG, then scroll to
RS232 OUTPUT. Each time you press ENTR the instrument transmits a 1 sec burst of lower
case "w"'s.
The green LED is connected to pin 2, if the switch is in the default DCE position. This is the pin
on which the M200A receives data. The LED is ON if an outside device is connected. This LED
gets its power from the outside device. When data is being transmitted by the outside device to
the M200A this LED will flicker.
When you are attempting to configure the RS-232 port, if either of the LED's go out when the
cable is connected, that generally means that there is a grounding problem. Switching the DCE-
DTE switch should fix the problem. See the schematic and assembly drawings in the appendix.
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The overall operation of this board is quite complex. To fully check it out in all of its operational
modes is not possible in the field. Therefore, a few simple tests are described here that test one
analog input channel, the 4 analog output channels, one digital input, and one digital output.
Each analog channel is routed through a programmable 16 channel multiplexer. Chances are
that if one channel works, they all work.
A. Turn on instrument.
B. Press TEST key on front panel keyboard until DCPS test is displayed.
C. The value displayed should read 2500 ± 200 mV.
If the M200A passes this test, it has successfully digitized a 2500 mV composite voltage
output from the Power Supply Module. The signal should also be quiet ± 25 mV.
In the DIAGNOSTIC menu on the front panel, there is a test that outputs a step voltage to the
4 analog outputs. This test is useful for calibrating chart recorders and dataloggers attached
to the M200A. The test can also be useful in diagnosing faults in the V/F board.
3. Select the ANALOG OUTPUT test. This causes the M200A to output a 5 step voltage
pattern to the 4 analog outputs on the rear panel. The status of the test is shown on the front
panel display. The scrolling can be stopped at any voltage by pressing the key below the
changing percentage display. The values are 0-20-40-60-80-100% of whatever voltage range
has been selected. For example the voltages would be 0, 1, 2, 3, 4, 5V if the 5V range had
been selected.
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4. Use a DVM on each of the analog output channels to confirm the correct voltages.
If the voltages step, but are the wrong values, the V/F board may be out of calibration. See
Section 9.3.3 for information on how to calibrate the V/F board.
The digital I/O section of the V/F board has 8 input bits and 24 output bits. Two of the 8
input bits are assigned as calibration controls. See Section 7.7 for information on calibration
using external contact closures.
There are 24 output bits on the V/F board. The 24 bits are made up of 3 - 8 bit ports. It is
possible for a single 8 bit port or even a single bit within a port to fail.
A quick observational test of the digital outputs is to observe the LED's in the Power Supply
Module (Refer to Figure 9-6 for the location of the LED's in the PSM) The state of the LED's
can be checked from Table 4-1. The comments section assumes the M200A has been running
for at least 45 minutes.
A more detailed test is in the DIAGNOSTIC menu. See Diagnostic tests in Section 9.1.3.
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Before the actual calibration is performed, switches on the V/F card must be correctly set and
jumpers set on the mother board. Jumper and switch setting changes must be performed with
the instrument power OFF.
Motherboard Jumpers
The motherboard contains 4 pairs of jumpers JP1 - JP8, one pair for each analog output channel.
Each channel can be configured for either voltage or current output. Use the Table 9-7 to
configure the jumpers.
There are 2 different types of current outputs, Non-Isolated (std equipment) and Isolated. Each
requires a different switch setting shown below. If you are operating the instrument in voltage
output mode, the switches should be set to the desired voltage range.
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*Required settings
1 V output
Switch State Comment
3 OFF Use for 1 V output
4 OFF Use for 1 V output
5 ON Use for 1 V output
6 OFF Use for 1 V output
100 mV output
Switch State Comment
3 OFF Use for 100 mV output
4 OFF Use for 100 mV output
5 OFF Use for 100 mV output
6 ON Use for 100 mV output
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1. After the switches and jumpers are set, turn on instrument power and complete the
following:
A. Press SETUP-MORE-DIAG, then press ENTR. Scroll to D/A CALIBRATION, press
ENTR.
B. Press ADC to select the first task, which is to calibrate the A/D converter.
C. Connect a DVM ground lead to TP3-AGND on the V/F board. Connect the positive lead
to TP9-DAC0.
D. The M200A will display a voltage near 1% of the voltage range set in the above
procedure. See Figure 9-4 for a table of approximate expected voltages. Adjust R27 until
the displayed voltage matches the DVM voltage, then press ENTR.
E. The M200A will display a voltage near 90% of the voltage range set in the above
procedure. Adjust R31 until the displayed voltage matches the DVM voltage, then press
ENTR. This step calibrates the instrument A/D converter to the external DVM.
F. The M200A will automatically scroll through the DAC output channels, calibrating each
one. The display will update the progress of the calibration. If operating all analog outputs
in voltage mode this completes the calibration procedure.
The calibration of each channel can be checked or recalibrated independently by scrolling the
PREV-NEXT buttons and pressing CAL for the desired channel. Also a DC offset bias can be
entered by pressing the OFFSET button for the appropriate channel.
1. BEFORE STARTING, make sure that hardware settings are correct as shown in Table 9-6
and Table 9-7.
2. Calibrate the A/D converter as described in item 2 above, if necessary.
3. Connect a 250 ohm resistor in series with a current meter to the correct pair of terminals on
the rear panel, see Table 9-8 for terminal assignments.
4. In the D/A calibration Menu press CFG, then use PREV-NEXT to select the channel to be
calibrated.
5. Press the SET button to select CURR for current loop operation, then press ENTR.
6. To enter the calibration routine press CAL.
7. To calibrate the 4 mA zero point, press the UP-UP10 - DN-DN10, then press ENTR.
8. The M200A will then output 20 mA. Press the UP-UP10 - DN-DN10 buttons to calibrate the
span point, then press ENTR.
9. Repeat steps 2-6 for each channel that needs to be calibrated.
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1. IZS temperature
2. Reaction Cell temperature
3. Box temperature
4. Spare
All 4 amplifiers have a single gain control - R34. If necessary, you can adjust the temperature
values by selecting the BOX TEMP - TEST function and adjusting R34 until the correct box
temp is shown. Remember that the temperature inside the case runs several degrees higher than
room temperature, which should be taken into account when setting BOX TEMP.
The voltages of the thermistor and thermocouple amplifier outputs are brought out to test points
on the edge of the board. Refer to the schematic 01086 for details. The voltages can also be read
using the DIAGNOSTIC - SIGNAL I/O feature. See Table 9-4 for details.
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1. Locate the Box temp thermistor on the board and place a calibrated thermometer near the
thermistor.
2. Select the BOX TEMP - TEST function on the front panel.
3. Adjust R34 until the front panel readout matches the thermometer readout. This will
cause all of the readouts to accurately measure their respective temperatures.
The buffer amplifier from the thermocouple amplifier to the CPU for the Moly temperature has a
gain adjustment. The voltage times 100 at pins 8-9 of U1 is the Moly temperature in degrees C.
For example 3.15 VDC at pin 9 of U1 is 315o C. The CPU is programmed to always drive the
temp to 315° C, so the voltage at U1 must be used as the absolute reference as to the correct
temperature. The temperature will vary ± 3 degrees due to the operation of the temperature
control loop in the CPU.
The temperature can be adjusted by the R6 pot on the Status/Temp board. To adjust the
molybdenum converter temperature:
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The output lines are opto-coupled NPN transistors which can sink 50 ma max of current with a
voltage of 30 VDC max.
The input lines are optically coupled with inputs pulled up to +5 VDC. External contacts can be
contact closures or open collector transistor contacts. DO NOT apply any voltage, since +5 VDC
is supplied internally.
Individual status lines can be set or cleared using the DIAGNOSTIC mode SIGNAL I/O. This
can be useful for simulating fault conditions in the analyzer to see if external circuitry is working
correctly. See Table 5-8 for pin assignments.
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The Linear Power Supply board can be tested by checking the DCPS - TEST function on the
front panel. It should read 2500 mV ± 200 mV. If the value is outside this range, individual
output voltages can be tested on connector P3, see Schematic in the Appendix for pinouts.
The Switching Power Supply output can be tested by observing the temperature of the PMT cold
block using the PMT TEMP - TEST function. The temperature should be constant 7± 2° C. The
output voltage can be observed on J10 of the Switch Board. It should be 15 VDC ± 0.5.
The Switch Board can be tested by observing the diagnostic LEDS along the top edge of the
board. The following Table 9-10 describes the typical operation of each LED.
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CAUTION - DANGER
Lethal voltages present inside Ozone Generator - DO NOT
defeat electrical interlock. Turn off instrument before
servicing. Unplug Generator before disassembling.
The ozone generator subsystem consists of a permeation drier, flowmeter, power supply -
generator module, and power switch. The location of the components is illustrated in Figure 9-7.
Ozone is generated by drying ambient air, passing the air between two electrodes that have a
large oscillating electric field generated by a high voltage transformer.
1. A leak or some other failure in the drier will let ambient air into the generator. There is
enough water vapor in room air to cause the generator to make nitric acid aerosol. It is very
corrosive and causes the generator cartridge to short out due to salt build-up. This reduces
the ozone concentration generated which can cause the analyzer to be non-linear due to
insufficient ozone concentration.
2. Blown fuse. The Ozone generator fuse is located on the upper end of the generator case.
3. Contaminated ozone generator cartridge. Dis-assemble and clean. Salts and oxgenated
hydrocarbons can be removed by rinsing with 10% nitric acid at 50° C.
4. Shorts, open circuits, arcing inside the case. Because of the very high voltages, metallic
components inside the ozone generator case can malfunction.
A. Disconnect power.
B. Remove ozone generator cover and inspect the wiring for evidence of arcing and open
circuits. Typically arcing due to high voltage has a dusty - burnt look. Look for these
areas inside the case and on the wiring that comes near the case.
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NOTE
The ozone generator is independently controlled in the SIGNAL I/O, OPTIC
TEST, and ELECTRICAL TEST diagnostics. After exiting these diagnostics,
the ozone generator is restored to the state specified by the above conditions.
Due to the large number of connections and fittings on the drier, the most common drier fault is
leaks. Before proceding with any other procedures check the drier for leaks.
Occasionally the drier gets contaminated. The manufacturer of the drier recommends replacing
the drier rather than trying to clean it. If cleaning is chosen, the following options are available:
1. Dirt - Clean any solids from dryer inlet by brushing. Use clean dry air to blow any loose
particles from the inlet. Deionized water or dilute (5-10% conc HCl in deionized water)
hydrochloric acid can be passed through the dryer. This should be done only with the dryer
and HCl at room temperature.
2. Organic liquids and freons - Rinse the inner and outer tubes using 1,1,1 trichlorethane.
Follow the solvent with dry air to purge the solvent.
3. Inorganic salts and oxgenated hydrocarbons can be removed by rinsing with 10% nitric
acid at 50° C.
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The above pressures and flows are filtered to produce the front panel readings. There is a small
delay after adjustment for a steady reading when observing the TEST functions.
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1. In SAMPLE mode, scroll the TEST functions to SAMP FLW. Observe the reading. Then
subtract the observed reading from the desired reading.
2. Go to the VARS menu by SETUP-MORE-VARS, then pressing ENTR. Scroll to
SFLOW_SET and press EDIT. The first value displayed is the SFLOW_SET:VALUE
reading, ADD the value from step 1 to the reading shown and key in the new reading, then
press ENTR. Check the low and high warning limits which are displayed as the next 2 values
to make sure the new value does not exceed the warning limits. Press exit to return to
SAMPLE mode.
3. Observe the SAMP FLW value. If necessary repeat step 2 to adjust the reading again to
match the desired flow rate.
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9.3.8.1 PMT
The PMT detects the light emitted by the reaction of NO with ozone. It has a gain of about
500,000 to 1,000,000. It is not possible to test the detector outside of the instrument in the field.
The best way to determine if the PMT is working is by using Optic Test. OT operation is
described in Section 9.1.3.3.
The basic method to diagnose a PMT fault is to eliminate the other components using ET, OT
and specific tests for other sub-assemblies.
1. Preamp, buffer amplifier, physical range control hardware for the PMT detector.
2. Precision voltage reference and voltage generation, and control for the PMT - HVPS
inside the sensor module.
3. Constant current generator and adjustment for the Optic Test LED.
4. Voltage generation and adjustment for Electric Test.
5. Thermistor amplifier, control signal generation for the PMT cooler.
The setup and adjustment of items 1-4 above is covered in the Factory Calibration procedure in
Section 9.1.6. Item 5 has no adjustable features.
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Adjustment of the HVPS is covered in the Factory Calibration Procedure in Section 9.1.6. To
troubleshoot the HVPS:
If any faults are found in the test, you must obtain a new HVPS as there are no user servicable
parts inside the supply.
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Sections 7.2, 7.3 show how the Z/S valve and IZS options should be set-up, and how to use them
with the AutoCal and Dynamic Cal features.
1. It is possible to manually toggle each of the valves using the SIGNAL I/O selection of
DIAGNOSTIC mode. Refer to Section 9.1.3 for information on using the DIAG mode. Also
refer to Figure 8-4, Figure 8-5, Figure 8-6 for a pneumatic diagram of the system.
The PTFE membrane of the permeation tube is affected by humidity. If the instrument is
installed in an air conditioned shelter, the air is usually dry enough to produce good results. If the
instrument is installed in a non-climate controlled site that has high humidity, variations in the
perm tube output will occur. For these sites, if high accuracy is required an additional source of
dry (dewpoint of -20 C or less) air, such as the M701 zero air module, should be attached to the
zero air scrubber inlet.
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The basic cause of many performance problems is a leak. Refer to Section 8.9 for the leak check
procedure.
9.3.10.2 Pump
The external sample pump is capable of maintaining the cell pressure at 5"Hg-A. If higher
pressures are noted, the pump may need servicing. Check the pump/ozone scrubber for leaks or
rebuild pump.
The internal sample pump pressures tend to run slightly higher than the external pump due to its
smaller size. As in the case above, if higher pressures are noted the pump may need servicing. In
the internal pump configuration, the ozone scrubber is integrated into the molybdenum
converter.
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Table 10-6: Teledyne API MODEL 200A Spares Kit for 1 Unit
Part No. Description
014040100 M200A Spares Kit for 1 Unit
Includes: Qty
012360000 Fan, Power Supply Module 1
013140000 Fan, PMT Cooler 1
CB0000001 FUSE O3, 1A 1
HE0000017 Heater, Reaction Cell, 12W 1
PS0000010 15V Switching Power Supply 1
RL0000015 Solid State Relay, 115 Vac 1
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